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CASTLETON
MEQUON

COLUMBUS
WEST VALLEY CITY

EDWARDSVILLE

PENDERGRASS

Magneto Power MWE Preferred Power Power Source Canada
Atlantic Power Central Power Systems SEDCO
9/09

1. Magneto Power, LLC Anoka (Minneapolis) MN 55303 Magneto Power, LLC 911 Lund Boulevard, Suite 300 Robert Moe 800-248-4016

Dallas TX 75235 Magneto Power, LLC of Texas 11011 Regency Crest Drive, Suite 100 Robert Ortolani 262-834-4394

Mequon (Milwaukee) WI 53092 Magneto Power, LLC 1000 W. Donges Bay Road, Suite 100 Robert Moe 262-834-4300

Tualatin (Portland) OR 97062 Magneto Power, LLC “West” 9991 S.W. Avery Street Greg Muse 800-338-5168

2. MIDWEST ENGINE WAREHOUSE Aurora (Chicago) IL 60504 Midwest Engine Warehouse-IL 700 Enterprise Street Tom Ziemann 630-862-3100

Edwardsville (KC) KS 66111 Midwest Engine Warehouse-KS 9630 Woodend Road Tom Ziemann 913-543-7600

Visalia CA 93291 Midwest Engine Warehouse-CA 7101 W. Doe Avenue John Reid 800-683-8484

West Valley City (SLC) UT 84120 Midwest Engine Warehouse-UT 3626 Parkway Boulevard Tom Ziemann 801-886-2350

3. PREFERRED POWER, INC Charlotte NC 28216 Preferred Power, Inc. 6509-A Northpark Boulevard Steve Krcelic 800-288-5310

4. POWER SOURCE CANADA, LTD Delta (Vancouver) BC V3M 6R9 Power Source Canada, LTD 300-1628 Derwent Way Mike Gulley 604-520-1294

Oakville (Toronto) ON L6H 6X5 Power Source Canada, LTD 2815 Bristol Circle, Unit 1 Mike Gulley 905-829-0006

5. ATLANTIC POWER, INC Castleton NY 12033 Atlantic Power, Inc. 20 Empire State Boulevard Art Falk 800-456-5692

6. CENTRAL POWER SYSTEMS Columbus OH 43228 Central Power Systems 3700 Paragon Drive Pat Earnest 614-534-2152

Tampa FL 33610 Central Power Systems of 4751 Oak Fair Boulevard Ray Coyle 614-534-2140
Florida

7. SEDCO, INC Pendergrass (Atlanta) GA 30567 SEDCO, Inc. 225 Henry D. Robertson Boulevard Wayne Crosby 800-346-4260

Pendergrass (Atlanta) GA 30567 SEDCO, Inc. 225 Henry D. Robertson Boulevard Mark Thomas 800-346-4260

01/11

ENGINE
ALTERNATOR
REPOWER GUIDE
Printed in the U.S.A.

BRIGGS&STRATTON CUSTOMER EDUCATION
CORPORATION post office box 702
milwaukee, WI 53201 USA
800 934 7730 | cust.ed@basco.com
MS-0415-02/11 Copyright ©2011. All rights reserved.

Briggs & Stratton
ThePowerPortal.com Alternator Chart
Your “One
YourStop” Information
“One Stop” Source
Information Source
Briggs & Stratton has developed a powerful and flexible private web-based portal for its You can order this chart from your source of supply or on
family of products, ThePowerPortal.com. ThePowerPortal.com under Customer Education.
MS-2288FL.qxp 10/23/2008 10:24 Page 1

Features
➤ Secure, on-demand, 24x7 access to meaningful
BRIGGS & STRATTON ALTERNATOR CHART
DC only Alternator

information and functions for all of our products. 0.5 Amp DC unregulated
Output @ 2800 rpm
Engine
97700
99700 White Connector
1 Red Wire
0.5 Amp DC unregulated Engine
110000
120000 White Connector
1 Black Wire
1.5 Amp DC unregulated Engine
12X400
15X400
1.2 Amp DC unregulated Engine
104700
130000
Diode 391507
3 Amp DC unregulated Engine
130200

100600 200000 20X400 Red Connector
100800 21X400 1 Black Wire
110000
Red Connector
120000

➤ Interact via the internet for a variety of
Diode 391507 2 Red Wires, 1 Black Wire

White Connector

business transactions.
1 Black Wire

691991 Since 1989
794103 Alternator outside the flywheel 791743 Since 2007 793640 Since 2007 494254 Since 1988 394250 Since 1979

System 3® / System 4®
➤ Here is a glimpse of the available features on 0.5 Amp DC unregulated
Output @ 2800 rpm
Engine
90000 Diode 391507
3 Amp DC unregulated Engine
110000
DC only Alternator
2 - 4 Amp DC unregulated Engine
110000
2 - 4 Amp DC unregulated Engine
170000
Red Connector
1 Red Wire
2 - 4 Amp DC unregulated Engine
170000
110000 120000 White Connector 120000 Red Connector 190000 190000

the brands for which you provide sales and/or 200000 1 Red Wire 150000 1 Red Wire 210000 210000
Diode 391507
White Connector 210000 200000 220000 220000
1 Black Wire Red
Connector 240000 240000
1 Red Wire
Diode 391507 250000 250000

service for: E-parts Look-Up
Diode 280000 280000
391507 300000 300000
310000 310000
326000 326000
350000 350000
380000 380000

• Brand specific product registration & rebate submission
Since 1981
397880 695730 Since 2000 694457 Since 1999 696578 Since 1973 393809 Since 1978
Alternator outside the flywheel

AC only Alternator Dual circuit Alternator
14 Volts AC Engine 2 – 4 Amp DC / 5 Amp AC Engine 2 – 4 Amp DC / 5 Amp AC Engine Diode 2 – 4 Amp DC / 5 Amp AC Engine 2 – 4 Amp DC / 5 Amp AC Engine
White Connector

• eClaim - electronic warranty claim filing for engines and
unregulated White Connector 14 Volts AC unregulated 14 Volts AC unregulated 14 Volts AC unregulated 14 Volts AC unregulated
160000 201000 1 Black Wire, 1 Red Wire 150000 391507 170000 Diode 15X000
1Black Wire
170000 1 Red Wire 210000 201000 White Connector 190000 391507 20X000
190000 Diode 391507 210000 1 Black Wire, 1 Red Wire 210000 21X000
210000 220000
White Connector

end products
White Connector 220000 240000
1 Black Wire Diode 391507 1 Black Wire, 1 Red Wire
243000 250000
250000 790292 280000
280000 790292 790292 290000 790292
310000 300000
320000 310000
400000 320000

• E-parts - service parts and/or whole goods look-up and ordering
420000 330000
460000 2 White 350000 2 White
2 White Connectors 2 White Connectors Connectors 380000 Connectors
Since 1974 1 Red Wire 1 Red Wire 1 Red Wire 46X700 793118 1 Red Wire
391595 698230 Since 2002 1 Yellow Wire 696742 Since 2002 1 Yellow Wire 696459 Since 2007 1 Yellow Wire Since 2007 1 Yellow Wire
Small magnets 1 Black Wire 1 Black Wire 1 Black Wire 795498 1 Black Wire

• Technical publications search 4 Amp Regulated Alternator
Brass Connector
Plastic sleeves Green Wires to regulator,
4 Amp DC regulated Engine
115400
5 or 9 Amp Regulated Alternator

Green Connector
5 or 9 Amp regulated, Tri-circuit
698315
Engine
110000
Green Connector
Black Wire
5 or 9 Amp Regulated or Tri-circuit Alternator
5 or 9 Amp DC regulated, Tri-circuit

698315
Engine
160000
117400 1 Black Wire 120000 691955 170000
1 Green, 1 Red between Armatures
190000
118000 150000 210000
185400 200000 220000

• Re-powering and replacement engine look-up 187400 210000
280000
300000
Diode 391507 691188
794360
Green Connector 1 Yellow Wire
250000
256000
280000
290000
Red Connector 1 Red Wire 300000
715200 691188 Small magnet 28 Volts AC 310000
794360 Tri-circuit Diode Wire 5 Amp DC regulated 320000
Green Connector Large magnet 40 Volts AC
330000

• 1,000s of technical and service documents
with 2 diodes leading to 1 Red Wire and 9 Amp DC regulated
Green Connector 350000
1 White Wire 380000
1 Yellow Wire
Red Wire = 2-5 Amp DC unregulated for
Red Connector 1 Red Wire 400000
battery charge
Yellow Connector
Small magnet 28 Volts AC
White Wire = 2-5 Amp DC negative for lights
420000
Since 1994 5 Amp DC regulated Since 1988 (5 & 9 Amp) 440000
715255 1 Red Wire, 2 Green Wires, 1 Black Wire 698314 Since 2002 Large magnet 40 Volts AC 696457
Small magnets 9 Amp DC regulated 1976 Tri-circuit 460000

10 Amp Alternator

what’s new?
Yellow Connector 10 Amp DC regulated Engine Black Connector 10 Amp DC regulated Engine Yellow Connector 10 Amp DC regulated Engine No Connector 10 Amp DC regulated Engine Yellow Connector 10 Amp DC regulated Engine
High Output 399916 To be ordered separately 2 Black Wires 399916 Shipped loose
2 Black Wires 110000 2 Black Wires 120000 117400 23X400 2 Green Wires 230400
Green Wires
120000 138400 24X400 240400
200000 185400
210000
691185 691185
691185

790325

Yellow Connector Yellow Connector Yellow Connector
2 Yellow Wires 2 Black Connectors 2 Yellow Wires 2 Yellow Wires
Red Connector 2 Black Wires, 1 Red Wire Red Connector Red Connector
Since 2000 Since 1974
695466 1 Red Wire 790320 Since 2004 715194 1 Red Wire 715798 Since 2001 715262 Since 1988 1 Red Wire
Small magnets Medium magnets

13 Amp Power Link™ Alternator
White Connector 115 Volts - 60 Hz, Engine 115 Volts 60 Hz, Engine 115 Volts 60 Hz, Engine White Connector 115 Volts 60 Hz, Engine
691573 13 Amp DC regulated White Connector 13 Amp DC regulated 691185 13 Amp DC regulated 2 Yellow Wires 697261 13 Amp DC regulated
Black Connector 44X700 2 Yellow Wires 35X400 305000 35X700
Ivory sheathed wires 697261 Black Connector
697261 Black Connector Orange Connector 356000 2 Red Wires, 1 Green Wire Orange Connector
2 Red Wires, 1 Green Wire 1 Orange Wire 1 Orange Wire
Black Connector Black Connector
1 Black Wire 1 Black Wire
White Connector Orange Connector Yellow Connector
2 Yellow Wires 1 Orange Wire 691573 2 Yellow Wires 697261
1 Red Wire Black Connector Red Connector 809176 White Connector 1 Blue Wire
1 Black Wire 697992 1 Red Wire
Connector Orange
1 Orange Wire White Connector 2 Red Wires
Yellow Connector Black Connector Black Connector
2 Black Wires White Connector

CHANGE BRAND FEATURE
697992 White Connector
1 Black Wire
Black Connector 697992 White Connector Yellow Sheath 1 White Wire,
2 Yellow Wires, 2 Red Wires, 1 Green Wire
White Sheath 1 Blue Wire White Connector 1 Blue Wire, 1 Red Wire 2 Yellow Wires 1 Black Wire, 1 Green Wire
White Connector 1 Blue Wire
White Connector 2 Red Wire White Connector 2 Red Wires, White Connector
White Connector 2 Red Wires 1 Red Wire, 1 Brown Wire,
Black Connector Black Connector Black Connector 1 Orange Wire
White Connector White Connector White Connector charge indicator light
Yellow Sheath 1 White Wire, Yellow Sheath 1 White Wire, Yellow Sheath 1 White Wire, 697992
697810 Since 2002 1 Black Wire, 1 Green Wire 841588 Since 2007 1 Black Wire, 1 Green Wire 841833 Since 2007 809175 Since 2007
1 Black Wire, 1 Green Wire

Update Literature from CE on your smartphone!
10, 13 and 16 A DC Regulated or Quad Circuit Alternator Engine
(10 A.) (16 A.)
14 Amp Regulated Alternator 20 Amp Regulated Alternator
Download a free app to your phone from 2dscan.com 691185 10, 13, 16 Amp DC regulated, Quad-Circuit 160000 220000
2 Blue Wires
14 Amp DC regulated Engine 20 Amp DC regulated Engine Black Connector 20 Amp DC regulated Engine
Yellow Connector (regulated battery charge but unregulated lights) 170000 250000 White Connector 2 Black Wires
Scan the tag to right. No smartphone? 2 Black Wires
Yellow Connector 2 Yellow Wires
190000 280000
430000
520000
2 Yellow Wires, 1 Red Wire 290000
303000
20H400
21A400
493219 220000 290000 691573 790325
Red Connector Red Wire 580000 310000
Text XXXXXXXX to 00000. Standard data rates may apply. Small Magnets = 20 Volts AC @ stator and
250000
280000
303000
310000 350000 2 Black
10 Amp DC regulated
Medium Magnets = 20 Volts AC @ stator 290000 320000 351000 Connectors
and 13 Amp DC regulated 303000 350000 380000 2 Black Wires
Large Magnets = 30 Volts AC @ stator and 691362 1 Red Wire
1 Red Wire
808877 16 Amp DC regulated 310000 380000 White Connector 470000
320000 400000 White Connector 2 Yellow Wires 540000
Yellow Connector Yellow Connector 2 Yellow Wires
2 Yellow Wires 330000 420000 1 Red Wire 1 Red Wire 610000 793660
Double White Connector 350000 460000 1 Black Wire
White Connector 1 Red Wire (charge) 1 Yellow Wire
1 Brown Wire 1 Blue Wire (charge indicator light)
380000 (QUAD) 2 Blue Wires
1 Orange Wire 400000 170000 1 Green Wire
1 Red Wire 420000 190000
Yellow Connector 2 Yellow Wires
10 A Since 1978 White Connector 460000 220000
397809 Black Wire = 8 Amp DC unregulated for lights (13 A.) 250000
696458 13 A Since 1979 Red Wire = 8 Amp DC regulated for battery 400000 280000 Since 1995 793658 2 Black Connectors
Update Literature from 16 A Since 1983
Quad Circuit Since 1984
Small magnets Quad Circuit
20 Volts AC @ stator
420000 460000 825004 Since 1998 825003 696579
Large magnets 795498
Since 2007 2 Black Wires, 1 Red Wire

CE on your smartphone!
20 - 50 Amp Regulated/ Inverter Alternator 40 Amp Alternator 60 Amp Alternator Flywheel / Magnets
Download a free app to your 20 -50 Amp DC regulated Engine 40 Amp DC regulated Engine 60 Amp DC regulated Engine
2 White Connectors
smartphone from 2dscan.com 2 Yellow Wires each 290000 430000 430000
300000 520000 520000
Scan the tag below 350000 580000 580000
380000
470000
540000
841170

For Engine Series V TWIN VANGUARD™:
• SMALL: 7/8” x 11/16” (22 x 18 mm) • SMALL: 7/8” x 21/32” (22 x 17 mm)
2 White Connector 825084 Since 2000 825479 Since 2002
• MEDIUM: 1-1/16” x 11/16” (27 x 18 mm) • MEDIUM: 7/8” x 29/32” (22 x 23 mm)
841178 Since 2004 4 Yellow Wires, 1 Red Wire 825524 Since 2002 825577 Since 2002 • LARGE: 1-1/16” x 15/16” (27 x 24 mm) • LARGE: 1-3/32” x 29/32” (28 x 23 mm)

Note : Unless specified, all tests must be carried out with the engine running at 3600 rpm.
The values indicated are minimium values. If the value measured is lower than www.thepowerportal.com
indicated a repeat test is advised before proceding any further.

MS-2288FL - 11/08

Table of Contents
Continuity Checks ‑ Switches ........................................................................................................................................ 2
DC Voltage Battery Test V .................................................................................................................................................. 2
Resistance Checks .............................................................................................................................................................. 2
Diode Checks ................................................................................................................................................................. 3
DC Shunt.................................................................................................................................................................................. 4
How Does A Shunt Work?...................................................................................................................................................... 4
DC Shunt Instructions............................................................................................................................................................. 7

No‑Load Starter Current Draw 12 Volt Starter Motors 300mV ................................................................................... 8
Starter Current Draw – 12 Volt Starter Motors 300mV ............................................................................................... 9
AC Voltage Output Check V .............................................................................................................................................10
DC Amperage Output Check ...................................................................................................................................11
Checking DC Amperage Output..........................................................................................................................................12
16 & 20 Amp Regulated Alternator......................................................................................................................................12
Starter Motor Current Draw 120 Volt Starter Motors A ..................................................................................................13
Alternator Identification..........................................................................................................................................................15
Engine/Alternator Replacement Information.......................................................................................................................17
Replacing Briggs & Stratton® Engines................................................................................................................................17
Briggs & Stratton® Engine/Replacing Engine Of Another Manufacturer..........................................................................20
6-Pin Deutsch Connector......................................................................................................................................................35
6-Pin Wire Harness...............................................................................................................................................................36
Typical 6-Pin Connector........................................................................................................................................................38
6-Pin Wire Harness With Efm..............................................................................................................................................39
Big Block™ Engine Typical 8-Pin Connector.......................................................................................................................41
Big Block™ Application (Equipment) Connector................................................................................................................41
Ferris®/Snapper Pro® Engine to Equipment Wire Harness..............................................................................................42
Alternator Harness and Repair Leads.................................................................................................................................44
Alternator Wire Assembly and Stop Wires..........................................................................................................................46
Wire Harness and Assemblies.............................................................................................................................................49
Performance Control Electronic Governor...........................................................................................................................50
Electrical Connector Method Of Crimping...........................................................................................................................51
Connector Crimping and Wire Stripping Tools....................................................................................................................51
AWG Wire Sizes ...................................................................................................................................................................53
Metric Wire Gauges ..............................................................................................................................................................53
Load Carrying Capacities ....................................................................................................................................................53
Glossary Of Terms.................................................................................................................................................................56

1

Insert BLACK test lead into COM receptacle in meter. Insert RED test lead into v    receptacle in meter.CONTINUITY CHECKS ‑ SWITCHES PUSH BUTTON ROTARY SWITCH KEY SWITCH (ELECTRIC 1. An incomplete circuit will be displayed as “OL”. 3. Attach test leads to component being tested. DC Voltage Battery Test RESISTANCE CHECKS 1. Rotate selector to V position. When meter test leads are attached to switch terminals and switch is in “ON” position. Insert RED test lead into v    receptacle in START) meter. no tone indicates no continuity (incomplete circuit). chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. 3. Rotate selector to position. TYPICAL 1 OHM RESISTOR FOR TRI-CIRCUIT ALTERNATOR Resistance Checks 2 . 4. 2. 2. a continuous tone indicates continuity. IGNITION STOP SWITCH 4. TOGGLE SWITCH Continuity Checks DC VOLTAGE BATTERY TEST V 1. Insert BLACK test lead into COM receptacle in LEAD meter. LEAD 2.(negative) terminal. Connect RED test lead to + (positive) terminal on battery and BLACK test lead to . Battery voltage can be checked as shown. Meter will display amount of ohms resistance in component being tested. Insert BLACK test lead into COM receptacle in meter. Insert RED test lead into v    receptacle in meter. Rotate selector to position. 3. Battery posts. 5. 4. WASH HANDS AFTER HANDLING. terminals and related accessories contain lead and lead compounds. With switch in “OFF” position.

) a. diode is installed LEAD FROM METER backwards. diode is defective “BUMP” ON CONNECTOR (open). If meter still displays “OL”. Insert RED test lead into v receptacle in A WIRE FROM STATOR meter. diode is OK.7 volt. If meter “beeps” once. Rotate selector to position. A continuous tone indicates continuity (shorted diode). 5. If meter displays “OL”. If meter “beeps” once. TEST An incomplete circuit (open diode) will be displayed LEAD FROM METER as “OL”. B 2. If meter makes a continuous tone. b. Attach RED test lead to point “A” and BLACK test lead to point “B”. the meter will display the forward voltage drop across the diode(s). the meter will LEAD FROM METER “beep” once. 1. diode is defective (shorted). b. If the TEST voltage drop is less than 0. c. (It may be necessary to pierce 3 Amp DC wire with a pin as shown. proceed to step 5. INDICATES DIODE SIDE A B DIODE TEST LEAD FROM METER WIRE CONNECTOR FROM STATOR Dual Circuit – Charging Unit TEST LEAD FROM METER WIRE TEST FOR CHARGING LEAD FROM CIRCUIT METER TEST LEAD FROM METER B DIODE A DIODE TEST A LEAD FROM WIRE METER FOR LIGHTING B CIRCUIT Tri-Circuit – Charging Circuit Tri-Circuit – Lighting Circuit 3 . Insert BLACK test lead into COM receptacle in meter. as well as display the voltage drop. DIODE CONNECTOR 4. Reverse test leads. 3. TEST a.DIODE CHECKS In the Diode Test position.

starter peak amp and steady amp draw. very leery of or at worst. rectifier is defective (“grounded”). RED Test Lead BLACK Test Lead Beep NOTE: Metal cased rectifiers must also be tested for “grounds”. touch each terminal. and alternator charging. and acknowledge that electricity has to follow strict physical properties. But once we have a basic understanding of electrical theory. with RED test lead C D Yes probe. The load in this case is the resistance to the flow of electrons through the shunt body between the posts. electrical testing becomes one of the easiest troubleshooting problems we will encounter. How Does A Shunt Work? Several years ago we introduced the 19359 DC Shunt as a complement to the Fluke Digital Multi-meter. we can test for system draw with the key switch off. A – D. This is actually a much safer approach than working with higher amperage. Though a very effective and useful tool. By using the DC shunt. The meter must be set to the millivolt scale in order to obtain the correct reading. Meter should display “OL” at each terminal. All of these tests can be done in about 30 seconds taking all the guess work out of the process. 4 . system draw with the key switch on. The DC shunt is a device that enables the technician to make several electrical tests with only one hook-up to the equipment. The two meter connecting posts are across part of the total load. as follows: B A Yes C B Yes With BLACK test lead probe contacting rectifier case. Electricity is one of those mysterious entities that most of us are at best. two questions usually come up: Why is a reading taken in millivolts to read amperage? Can I use the shunt with another brand of meter? The shunt works by adding a measured load (resistance) to a DC series circuit. down right frightened of. Any load in a circuit will cause a voltage drop across that particular part of the total load. D A Yes If meter makes a continuous tone at any terminal. A D B C 120 Volt Rectifier DC SHUNT Have you ever wanted one tool in your toolbox that would make your life so much easier that it would pay for itself after the first couple of uses? That tool might well be the 19359 DC shunt.

= ----------------- 1 milliohm 0.001 ohm The above equation shows that across the posts on the Briggs & Stratton shunt.001 volt. OHM'S LAW FORMULA Some background information may help to make this clearer. When we use the shunt to check the alternator charge rate. 5 .001 amp or one milliamp. Also. For example. one millivolt is 1/1000th of a volt or 0. This is why the test meter is set to the millivolt range. 1 volt = 1 amp x 1 ohm The DC shunt is designed to have a predetermined resistance of 0. Expressed mathematically. 1/1000 of an amp equals 0. FOR BLACK LEAD FROM METER RESISTANCE FOR RED LEAD SECTION FROM METER CONNECTS TO NEGATIVE BATTERY CABLE CONNECTS TO NEGATIVE BATTERY POST Previous Style Current Style Note: Meter and battery connections to shunt are the same as the previous DC shunt as shown above.001 inch could be called a milliinch. The prefix “milli” is Latin for 1/1000 of a unit. E=IxR or volts equals amps multiplied by resistance. 0. amps is the unknown. Ohm’s Law states that 1 volt of electrical pressure is required to move 1 amp of current (electron flow) through 1 ohm of resistance. Therefore. Changing Ohm’s Law around to determine the current gives us: 1 volt 1 amp = --------- 1 ohm Let’s take a look at units of measure. 1 milliohm equals 1 amp of current flowing in the circuit. Applying these units of measurement for Briggs & Stratton shunt into Ohm’s Law gives us: 1 millivolt 0.001 volt 1 amp = ----------------.001 ohm between the meter connection posts.

Now, let’s add charging current from the alternator system flowing through the shunt. Resistance through the
shunt will stay the same. We know the current will change. Since the shunt measures voltage drop, we have
to be interested in the voltage or pressure in the system. The resistance value of the shunt is set so that we
know there is a 1 to 1 ratio between amps and millivolts. Therefore, a reading of 2 millivolts on the meter face
is equal to 2 amps of current, 3 equals 3, etc.
From this discussion, it should be clear that any meter capable of reading millivolts can be used with the DC
shunt.

6

DC SHUNT INSTRUCTIONS
The DC shunt, part number 19468 readily adapts
to standard mount, side mount or tab type battery
terminals. The shunt must be installed on the
- (negative) terminal of the battery.
For standard terminals, attach ring terminal on shunt
to post terminal on battery. For tab terminal batteries, LEAD

attach shunt to battery terminal using 1/4" – 20 stud
and wing nut. For side terminal batteries, remove LEAD

post terminal from shunt and thread into side terminal
on battery. Attach battery cable to shunt using
3/8" – 16 nut from post terminal.
The Digital Multimeter will withstand DC input of
10 – 20 Amps for up to 30 seconds. To avoid blowing NEGATIVE
BATTERY
fuse in meter, use the DC shunt when checking TERMINAL

current draw of 12 volt starter motors or DC output
on 16 Amp regulated alternator.
2. Insert RED test lead into v receptacle in
Charging output can be checked with the engine meter and RED receptacle on shunt.
running. All connections must be clean and tight for
3. Insert BLACK test lead into COM receptacle in
correct amperage readings.
meter and BLACK receptacle on shunt.
1. Install shunt on negative battery terminal. 4. Rotate selector switch to 300mV position.

ATTACH NEGATIVE
BATTERY CABLE
NEGATIVE BATTERY
TERMINAL

ATTACH NEGATIVE
BATTERY CABLE
NEGATIVE BATTERY
TERMINAL

ATTACH
NEGATIVE
BATTERY
CABLE WITH
3/8"-16 NUT
NEGATIVE BATTERY
TERMINAL

Standard Mount Tab Mount Side Mount

7

NO‑LOAD STARTER CURRENT DRAW
12 VOLT STARTER MOTORS 300mV TEST LEAD
TEST FROM
(STARTER MOTOR REMOVED FROM ENGINE) LEAD FROM METER
METER
To check the no-load amperage draw of a 12 volt
starter motor that is removed from the engine, a PRESS TO
START
fixture as shown in the figure should be used. See
the diagram for the parts necessary to make a test
set-up.

CAUTION: DO NOT clamp motor housing
in a vise. Starter motors contain two ceramic
magnets which can be broken or cracked if
the motor housing is deformed or dented.
NOTE: When checking starter current draw, battery
NOTE RPM OF
voltage must not be below 11.7 volts. STARTER MOTOR
TACHOMETER
1. Install shunt on - (negative) battery terminal.
2. Insert RED test lead into v receptacle in 12 Volt Starter Current Draw – DC Shunt
meter and RED receptacle on shunt.
3. Insert BLACK test lead into COM receptacle in DRILL TWO HOLES – 3/8" DIA.
EXTRA HOLE FOR FOR STARTER MOUNTING
meter and BLACK receptacle on shunt. MOUNTING STARTER BRACKET
BRACKETS PART NUMBER 392749
DRILL TWO HOLES
2-1/4" FOR MOUNTING
57.2 MM BRIGGS & STRATTON
“L” 4" PART NUMBER 19200
102 MM TACHOMETER #7
DRILL TAP HOLE FOR
3-1/2" 1/4-20 NC SCREWS
89 MM

3-1/2"
89 MM
1"
25.4 MM
10"
254 MM

METAL STOCK – 1/4" THICK STEEL
2"
51 MM
TEST BRACKET

Starter Motor Housing Length How to Make the Test Mounting Bracket

TABLE 1
12 VOLT STARTER MOTOR SPECIFICATIONS
MOTOR HOUSING LENGTH MINIMUM RPM MAXIMUM AMPERAGE
3" (76 mm) 6500 18
3-5/8" (92 mm) 6500 18
3-3/4" (95 mm) 6500 19
4-3/8" (111 mm) 6500 20
4-1/2" (114 mm) 6500 35

4. Rotate meter selector to 300mV position. Table 1 for test specifications for starter motor
5. Activate the starter switch: being tested.
a. Note RPM on vibration tachometer. 7. If the starter motor does not meet the
b. Note amperage on meter. specifications shown in the chart, refer to the
Repair Instruction Manual, Section 7, for service
6. Note starter motor housing length and refer to and repair procedure.
8

such as the battery. Tool part number 19368. cables. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt. Install shunt on . the procedure is similar to checking the starter motor off the engine. The battery cable and key switch harness installed in the TEST LEADS FROM equipment may be substituted for the test harness IGNITION TESTER TOOL PART METER shown. make sure the test is performed with the correct oil in engine. Note amperage on meter. If the amperage draw exceeds 100 amps and the engine RPM is less than 350. Note RPM on vibration tachometer. NUMBER 19368 When making this current draw test. Remove the spark plug(s) and ground the spark plug wire(s) using Ignition Tester(s). solenoid and connections. Insert RED test lead into v receptacle in meter and RED receptacle on shunt. Activate the starter switch: a. 6. Rotate meter selector to position.STARTER CURRENT DRAW – 12 VOLT STARTER MOTORS 300mV (STARTER MOTOR MOUNTED ON ENGINE) To check the amperage draw of a starter motor mounted on the engine. 2.7 volts. 3. 12 Volt Starter Current Draw – DC Shunt 1. battery voltage must not be below 11. On all 12 volt starter systems. 4. amperage draw and TERMINAL battery voltage. Note: When checking starter current draw. it is important NEGATIVE BATTERY to monitor the engine RPM. Section 7. 9 . 5. it could indicate a starter motor problem. Then proceed to check the starter motor by performing the no-load starter motor test as indicated on page 8 or refer to the Briggs & Stratton Repair Instruction Manual.(negative) battery terminal. Also the engine temperature should be at least 68 to 70° F (20° C). Check the starting system. b. and belts removed from the PTO shaft.

TABLE 2 YELLOW GREEN WHITE CONNECTOR CONNECTOR CONNECTOR ALTERNATOR AC OUTPUT AT 3600 RPM AC ONLY 14 VOLTS DUAL CIRCUIT 14 VOLTS • 5 AMP REGULATED 28 VOLTS ATTACH METER TEST TEST • 9 AMP REGULATED 40 VOLTS TEST CLIPS CLIP CLIP TRI-CIRCUIT 28 VOLTS QUAD-CIRCUIT 10 AMP CIRCUIT SINGLE CIRCUIT 9 AMP REGULATED 16 AMP CIRCUIT TRI-CIRCUIT AC ONLY QUAD-CIRCUIT 30 VOLTS • 10 AMP REGULATED 20 VOLTS AC Voltage Output Check • 16 AMP REGULATED 30 VOLTS • 16 AMP REGULATED 26 VOLTS • 20 AMP REGULATED 29 VOLTS 5 VOLTS - • 20-50 AMP REGULATED From each winding • Alternator output is determined by. With engine running at 3600 RPM. 5. flywheel. RED CLIP TO 3. Attach BLACK test clip to engine ground. Rotate selector to position. Note: When checking AC voltage output of stator on 10-16 and 20 amp regulated or Quad- Circuit alternator systems. alternator and magnet size. 10 . CONNECTOR 2. attach one meter test clip to each output pin terminal in yellow connector from stator. Test clip leads may be attached to either output pin. AC SIDE OF HARNESS (BLACK WIRE) 4. Insert BLACK test lead into COM receptacle in meter. Insert RED test lead into v receptacle in CIRCUIT WHITE meter. AC output TEST CLIP TO A GOOD GROUND reading should be close to specification listed for SURFACE TEST CLIP TO AC OUTPUT PIN alternator type in Table 2.AC VOLTAGE OUTPUT CHECK v DUAL 1. Attach RED test clip to alternator AC output terminal(s). 6.

5 AMP DC ONLY (VANGUARD™) (1. 5. At step 5. SYSTEM 3 & 4 . TO DC OUTPUT PIN 4. Attach BLACK test clip to + (positive) battery terminal. Be sure ** Amperage will vary with battery voltage. TEST LEAD 3. rectifier may be damaged. (See note for System 3 & 4 alternators. DC Amperage Output Check TABLE 3 ALTERNATOR TYPE DC OUTPUT 1/2 AMP. Rotate selector to position. Attach RED test clip to DC output terminal.5 AMP DC ONLY (3 AMPS) **2–4 AMPS DUAL CIRCUIT **2–4 AMPS TRI CIRCUIT 5 or 9 AMP DUAL CIRCUIT 5 AMP DC *QUAD-CIRCUIT **3–8 AMPS *5 AMPS REGULATED **3–5 AMPS *9 AMPS REGULATED **3–9 AMPS *10 AMPS REGULATED **3–10 AMPS *16 AMPS REGULATED **3–16 AMPS *20 AMPS REGULATED **3–20 AMPS * Connect test leads before starting engine.) 6.DC AMPERAGE OUTPUT CHECK See Note Below For 1/2 Amp and System 3 “BUMP” ON CONNECTOR & 4 Alternators INDICATES THE DC OUTPUT PIN LOCATION AC See Page 12 for Special Instructions on Checking OUTPUT PIN DC Amperage Output of 16 and 20 Amp Regulated System 1. attach BLACK test clip to ground. with engine running at 2800 RPM.2 AMP DC ONLY (MODEL 130000) (1. DC output reading should be close to specifications listed for alternator type shown in Table 3. With engine running at 3600 RPM. DC CIRCUIT SYSTEM OUTPUT 2. Insert BLACK test lead into COM receptacle in PIN meter.5 AMP) 1. 11 . Insert RED test lead into receptacle in DUAL meter.5 amp. the amperage will be loose while engine is running. NOTE: 1/2 AMP AND SYSTEM 3 & 4 DC AMPERAGE OUTPUT CHECK: Follow DC output check procedure as described above through step 4. If battery connections are secure. If a test lead vibrates voltage is at its maximum.2 AMP) 1. BATTERY TERMINAL DC output should be no less than 0. the regulator/ less than the higher value shown. LEAD TO POSITIVE At step 6.

Install shunt on negative battery terminal. DC output reading should be close to specifications listed in DC Amperage Output Check Table 3.(negative) terminal of the battery. The DC Shunt must be installed on the . PART NUMBER TERMINAL 19468 5. 16 and 20 Amp System – DC Shunt 12 . TERMINAL DC SHUNT 4. Tool part number 19468. With engine running at 3600 RPM. 1. Insert RED test lead into v receptacle in meter and RED receptacle on shunt.CHECKING DC AMPERAGE OUTPUT TEST LEAD 16 & 20 AMP REGULATED TEST LEAD ALTERNATOR To avoid blowing fuse in meter when testing DC output of 16 and 20 amp system the DC Shunt. 2. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt. 3. All connections must be clean and tight for correct amperage readings. is required. Rotate selector to 300mV position.

Insert white test lead from adapter.5 7800 J282188 Briggs & Stratton 2. Tool part ACTIVATE STARTER number 19358. When meter reading stabilizes. Section 7. 9. Plug the adapter cord (male end) into the previously tested wall outlet. Depress starter switch button. RPM should be close to specifications listed in Table 4.5 7400 SME–110–C6 SME–110–C8 American Bosch 3. Tool part number 19358. Table 4.45 mm) Motor Housing 8.STARTER MOTOR CURRENT DRAW CAUTION: If amperage is higher than 120 VOLT STARTER MOTORS A specification in Table 4. Tool part number 19358. The following test procedure must be AC LINE VOLTAGE MUST used to avoid any accidental shock BE NO LESS THAN 110 VOLTS hazard to the service technician. If the starter motor does not meet the given check RPM using vibration tachometer. PUSH SWITCH TO 1. motors. If starter motor amperage is within specification. into the COM receptacle in meter. Use the same test fixture used in the 12 volt starter test to check the current draw and free running RPM of motor.0 7400 06026–28–M030SM Mitsubishi 3. (approximately 3 seconds) 120 Volt AC Starter Motor Current Draw amperage should not exceed the specification with Line Current Adapter shown in Table 4. 3. Rotate selector to A position. refer to the Repair Instructions number 19200. 2. indicates a shorted when checking current draw on 120 volt starter starter motor. Plug the adapter cord (female end) into the switch box receptacle of the starter motor. TACHOMETER READ RPM OF STARTER MOTOR 7. Refer to specifications. 10.7 6500 3-1/2˝ (75. 6. and note maximum allowable amperage draw for motor being tested. Manual. 5. Tool part specifications. which could be dangerous. Insert BLACK test lead from adapter. TABLE 4 120 VOLT STARTER MOTOR SPECIFICATIONS STARTER MOTOR MAXIMUM MINIMUM IDENTIFICATION AMPERAGE RPM American Bosch SME–110–C3 3. than number in chart. immediately stop the test! An amperage reading higher Use Line Current Adapter. 13 . into the receptacle in meter. 4.

Ring Gear) 696540 (Roll Pin Type) 252700-252799 693551 (Steel Ring Gear) 693713 (Steel Ring Gear) 693699 (Steel Ring Gear) 253700-253799 795121 (Plastic Ring Gear/Starter Housing is Over 4" in Length) 194700-198799 795121 (Alum. Ring Gear) 312700-312799 693551 (Steel Ring Gear) 693699 (Steel Ring Gear) 693713 (Steel Ring Gear) Opposed Twin Cylinder Engines 400400-422499 497596 (3 5/8" Housing) 695708 696541 (C Ring Type) 400700-422799 498148 (4 3/8" Housing) 696540 (Roll Pin Type) 42A700-42E799 496181 (Steel Pinion Gear) 406700-461799 V-Twin Vanguard™ Engines 303400-303499 499521 695708 696541 (C Ring Type) 354400-354499 691564 (Steel Pinion Gear) N/A (Steel Pinion Gear) 496881 (Steel Pinion Gear) 350700-350799 380400-381499 380700-381799 303700-303799 499521 695708 696541 (C Ring Type) 304400-304499 691564 (Steel Pinion Gear) N/A (Steel Pinion Gear) 496881 (Steel Pinion Gear) 350400-350499 351400-351499 351700-351799 381400-381499 691564 (Steel Pinion Gear) 695708 696541 (C Ring Type) 381700-381799 V-Twin Intek™ Engines 405700-405799 499521 695708 696541 406700-406799 407700-407799 445700-445799 Drawings on next page 14 .120 Volt Starter Kit 12B400 754185 (Kit) 390922 (Starter Motor Only) 12C300 754185 (Kit) 12C400 754185 (Kit) 12D300 754185 (Kit) 12D400 754185 (Kit) Snow Engines . Ring Gear/Starter Housing is Over 4" in Length) 195400-195799 693552 (Steel Ring Gear/Starter Housing is Over 4" in Length) 19E400-19E499 19F400-19F499 19G400-19G499 19K400-19K499 280700-289799 28A700-28W799 Single Cylinder Intek™ Engines 120100-15D100 793667 120 volt (60Hz Starter Assembly) 699786 230 volt (50Hz Starter Assembly) 20A100-21P200 795909 120 volt (60HZ Starter Assembly) 792157 230 volt (50Hz Starter Assembly) 310700-310799 497595 (Plastic Ring Gear) 695708 (Plastic Ring Gear) 696541 (C Ring Type) 311700-311799 497595 (Alum. Ring Gear) 695708 (Alum. # (Bendix) Snow Engines .230 Volt Starter Kit (Europe Only) Models 12 & 15 699786 (Kit) 390922 (Starter Motor Only) Series 800 & Series 1100 Models 20 & 21 792157 (Kit) Series 1300 & Series 1500 Single Cylinder Engines 190400-196499 693054 (Plastic Ring Gear) 695708 (Plastic Ring Gear) 696541 (C Ring Type) 190700-195799 693054 (Alum. Ring Gear) 695708 (Alum. Electric Starter Kits Quick Reference Engine Model Starter Assembly# Starter Gear Only# Drive Assy.

Knowing the type of alternator system an STATOR OUTPUT WIRE(S) AND CONNECTOR (TYPICAL) ONE LEAD FROM ENGINE (STATOR) ONE LEAD FROM ENGINE (STATOR) CONNECTOR TO EQUIPMENT HARNESS CONNECTOR TO EQUIPMENT DIODE OUTPUT LEAD HARNESS AC Only DC Only • 14 Volts AC for lighting circuit. • One BLACK lead from stator. thrower with a single headlight requires an AC Only system. • 3 amp DC unregulated for charging battery. 15 . RETAINING RING CLUTCH STARTER DRIVE RETAINER DUST COVER DRIVE ASSEMBLY ROLL RETAINING RING PINION PIN-SLOT RETURN SPRING UPPER RETAINER GEAR UP SPRING FLAT WASHER WASHER LOWER CLUTCH BEVELED EDGE UP RETAINER WAVE WASHER STARTER STARTER MOTOR CLUTCH PINION GEAR HELIX C-Ring Type Roll Pin Type Steel Ring Gear ALTERNATOR IDENTIFICATION Briggs & Stratton engines are equipped with a engine is equipped with is important. whereas a snow the connector. • One RED lead from stator. • White connector output lead. particularly number of different alternator systems to meet the when an engine is being replaced. • RED connector output lead. requirements of equipment manufacturers. • Diode encased at connector. For Briggs & Stratton alternator systems are easily example. a large lawn tractor with accessories may identified by the color of the stator output wire(s) and require a 16 amp regulated system.

(STATOR) codificación de color y regulador / rectificador. 16 . • Conector AMARILLO con dos terminales • Dos conductores AMARILLOS conducen al regulador / rectificador. INDICATES DC OUTPUT • Green connector. LEAD 5 AMPS DC (+) CONNECTOR • Un cable rojo del regulador/rectificador al cable de salida TO BATTERY AND CLUTCH CIRCUIT del conector ROJO. • Blue charge indicator wire to white connector. • 10 o 16 amperios DC regulados para cargar la batería. • Charge indicator light and wiring supplied by • Uses same stator as Tri-Circuit system. • Uses same stator as 10 and 16 amp system. • La salida del alternador viene determinada por el tamaño del imán del alternador del volante. • One BLACK lead from stator. REGULATOR/ RECTIFIER TWO YELLOW LEADS • 14 Volts AC for lighting circuit (ONE BLACK lead from stator). • Two diodes encased in wire harness. flywheel alternator magnet size. CONNECTOR LEAD TO EQUIPMENT FROM ENGINE HARNESS (STATOR) CONNECTOR CONNECTOR YELLOW TWO YELLOW WIRE LEADS CONNECTOR REGULATOR/ RECTIFIER 493219 Regulator/Rectifier 5 or 9 Amp Regulated Used With Charge Indicator Circuit • 5 or 9 amp DC regulated for charging battery. CHARGING INDICATOR • RED and white output leads. equipment manufacturer. • Green connector. HARNESS RED WIRE AND RAISED RIB • One BLACK lead from stator. 10 OR 16 Amp Regulated • White connector with two pin terminals. • Diode encased at connector. LEAD DC LEAD AC OUTPUT OUTPUT TO EQUIPMENT HARNESS LEADS FROM ENGINE (STATOR) CONNECTOR OUTPUT LEAD DC CHARGING CIRCUIT ONE RED RED LEAD TWO BLACK LEADS LEAD FROM ENGINE (STATOR) CONNECTOR TO EQUIPMENT HARNESS LEAD AC FOR LIGHTS Dual Circuit • 3 amp DC unregulated for charging battery CONNECTOR (ONE RED lead from stator). Tri-Circuit TO EQUIPMENT • 10 amp AC. TO EQUIPMENT HARNESS 5 AMP DC (-) TWO DIODES ENCASED TO LIGHTS WHITE LEAD IN WIRE HARNESS • 2 cables NEGROS del estator. • Alternator output (5 or 9 amp) is determined by • DC output the same as 10 or 16 amp system. • RED DC output wire to white connector. ONE BLACK LEAD FROM ENGINE • 10 y 16 amperios utilizan el mismo estator.

all of the alternator systems referred to in this book have a battery as part of the electrical system. The 9 and 16 amp regulated systems use flywheels with the large alternator magnets. For the equipment to function. the original engine may have been equipped with a Dual Circuit system and the replacement engine is equipped with a regulated system. This means that the output connector on the replacement engine is not compatible with the original wiring harness on the piece of equipment. sometimes the newer engine has an alternator system different from the alternator system on the original engine. When replacing an engine in these applications. We can integrate the two systems by making an adapter harness from readily available parts. The regulator/rectifier prevents the battery from being over charged. Generally an unregulated DC system (DC Only. because the equipment requirements are usually much less on an unregulated DC system. However. *Small Magnet 7/8" x 11/16" (22mm x 18mm) *Large Magnet 1-1/16" x 15/16" ALTERNATOR MAGNETS (27mm x 24mm) *V Twin Alternator Magnet Size: Small 7/8" x 21/32" (22 mm x 17 mm) Large 7/8" x 29/32" (22 mm x 23 mm) 17 . See figure below for magnet sizes. Dual Circuit) should not be used to replace a regulated system because alternator output may not be sufficient for equipment requirements. For example. a regulated system may be used as a replacement. Tri-Circuit as well as the 5 and 10 amp regulated systems use flywheels with small alternator magnets. DC Only.ENGINE/ALTERNATOR REPLACEMENT INFORMATION With the exception of the AC Only alternator. the alternator must be the same as the original. NOTE: The AC Only. An example would be certain generators or welders that use alternator output to excite an electrical field. Replacing Briggs & Stratton® Engines When replacing an older Briggs & Stratton engine on a piece of equipment with a newer Briggs & Stratton engine. Dual Circuit. the alternator output must be very evenly matched to the equipment requirements. There are specialized applications that use an alternator without a battery.

splice 393537 connector into RED DC wire and connect to equipment harness. 2 18 .FEMALE AC DC SPLICE 393537 . splice 393537 connector into white AC wire and connect to equipment harness.FEMALE DUAL CIRCUIT CONNECTOR .DUAL CIRCUIT REPLACEMENT CONNECTOR HARNESS EQUIPMENT HARNESS . Original engine equipped with DC Only alternator. Then. Replacement engine equipped with Dual Circuit alternator.MALE 398661 (FROM ENGINE) HARNESS . Modify 398661 harness supplied with replacement engine by removing white AC wire. Replacement engine equipped with Dual Circuit alternator.GREEN DIODE RIB BLACK WIRE CONNECTOR .DUAL CIRCUIT WHITE CONNECTOR REPLACEMENT CONNECTOR HARNESS AC WHITE WIRE DUAL CIRCUIT CONNECTOR .GREEN BLACK WIRE RIB CONNECTOR . 2 393456 .The following are alternator replacement combinations which require an adapter harness.FEMALE DC RED WIRE AC DC RIB SPLICE 393537 . 1. Then.MALE RIB DIODE Fig.MALE WHITE CONNECTOR 398661 (FROM ENGINE) HARNESS . See Fig. 1 2. 1 EQUIPMENT HARNESS .FEMALE 393456 . Modify 398661 harness supplied with replacement engine by removing RED DC wire. All of the necessary components are shown. See Fig. Original engine equipped with AC Only alternator.MALE Fig.

MALE SPLICE RED WIRE 692306 RED WIRE BLACK WIRE RIB RIB RED CONNECTOR HARNESS . Replacement engine equipped with 5. SPLICE LIGHTING CIRCUIT WIRE OUTPUT CONNECTOR FROM REGULATOR .3. Connect to equipment harness.FEMALE END PROFILE MALE FEMALE Fig.FEMALE FROM REGULATOR . See Fig. 9. Original engine equipped with Dual Circuit alternator. See Fig. 3 NOTE: THE DIODES MUST BE REMOVED FROM THE EQUIPMENT HARNESS. Original engine equipped with Tri-Circuit alternator. Modify 692306 harness supplied with replacement engine by splicing in 399916 connector assembly. 4 NOTE: THE DIODES MUST BE REMOVED FROM THE 692306 HARNESS BEING CONNECTED TO THE EQUIPMENT HARNESS. 9. 10 or 16 amp regulated system. Modify 692306 harness supplied with replacement engine by splicing into charging circuit wire and lighting circuit wire in equipment harness.FEMALE CHARGING CIRCUIT WIRE Fig. 4 19 .MALE EQUIPMENT HARNESS RED WIRE 692306 RED CONNECTOR HARNESS . 3 4. 10 or 16 amp regulated system.MALE 398661 EQUIPMENT OUTPUT CONNECTOR HARNESS . Replacement engine equipped with 5. 399916 CONNECTOR ASSEMBLY .

5. Direct Replacement. Connect to equipment harness. Replacement engine equipped with Tri-Circuit alternator. Replacement engine equipped with 9 or 16 amp regulated system. Original engine equipped with 5 amp regulated system.EQUIPMENT HARNESS . Often the equipment wiring harness is not compatible with the Briggs & Stratton alternator output harness. Discard 691955 diode harness supplied with new engine. 9. Add 692306 harness and modify by splicing in 399916 connector assembly. 10. See Fig.MALE SPLICE RIB 692306 BLACK RIB HARNESS . 9. Original engine equipped with 9 amp regulated system. Connect to equipment harness. 5 6. Connect to equipment harness. Direct Replacement. Discard 691955 diode harness supplied with new engine. Install 794360 regulator/rectifier. 10 or 16 amp regulated system. Replacement engine equipped with 10 or 16 amp regulated system. To do this. The following alternator replacement combinations require no modifications.FEMALE WIRE 398661 . 7. To create a compatible system it may be necessary to modify the equipment wiring harness. Original engine equipped with 5 amp regulated system. Direct Replacement. Replacement engine equipped with 5. the equipment requirements must be known so that the replacement alternator system has the same output as the original system provided. 8.MALE 393537 . Original engine equipped with 10 amp regulated system. Connect to equipment harness.FEMALE 794360 REGULATOR/RECTIFIER Fig. Direct Replacement. Even though the keyswitch harness connectors 20 . The original keyswitch may also create a challenge. Connect to equipment harness. Connect to equipment harness. 10 or 16 amp regulated system. 5 399916 CONNECTOR ASSEMBLY . Transfer 491546 regulator/rectifier from original engine to the new engine. BRIGGS & STRATTON® ENGINE/REPLACING ENGINE OF ANOTHER MANUFACTURER When replacing the engine of another manufacturer with a Briggs & Stratton engine.OUTPUT CONNECTOR FROM REPLACEMENT ALTERNATOR . Replacement engine equipped with 9. Replacement engine equipped Tri-Circuit alternator. Original engine equipped with DC Only alternator. a wiring diagram for the equipment is essential. Original engine equipped with Dual Circuit alternator.

However. that when the “brand X” keyswitch is in the START position there is no battery voltage available to the #2 switch terminal. For example. Terminal Function NO. This is a "Truth Table" Briggs & Stratton KEY Switch 5 Terminal Positions L M L M L M Terminal Function 2 3 2 3 2 3 4S 4S 4S No. The wiring diagrams show the type of keyswitch that is compatible with the alternator system shown. L M L M L M 1 Ground (Used only with insulated panel) 2 3 2 3 2 3 4 4 4 2 To Carburetor Solenoid 1 5 S 1 5 S 1 5 S G A G A G A 3 To Stop Switch Terminal On Engine 6 A 6 A 6 A 4 To Solenoid (Tab terminal) OFF RUN START 1-6-3 2-5-6 2-4-5 5 To Battery (Battery terminal on solenoid) Figure 8 6 To Alternator (DC Output) Part# 692318 21 . see the 5 terminal switch diagrams in Figure 1 and Figure 2. if the replacement Briggs & Stratton engine was equipped with a carburetor solenoid. shown in Figure 1 has been replaced by a 6 terminal keyswitch. 1 5 1 5 1 5 G B G B G B 1-G Ground (Used only with insulated panel) 2-L To Carburetor Solenoid OFF RUN START 3-M To Stop Switch Terminal On Engine Figure 6 4-S To Solenoid (Tab terminal) Part# 490066 5-B To Battery (Battery terminal on solenoid) Brand X KEY Switch 5 Terminal Positions Terminal Function M R M R M R No. or replace the keyswitch with one that is compatible with all Briggs & Stratton alternator systems. Therefore it is necessary to have a diagram of the keyswitch showing the terminal positions and their functions. This is why it is important to have a diagram of the keyswitch when replacing engines. Consequently. NOTE: The 5 terminal Briggs & Stratton keyswitch. The keyswitch in Figure 1 is compatible with all Briggs & Stratton alternators. part number 692318. there are internal differences to keyswitches. 2 3 2 3 2 3 4S 4S 4S 1-A Accessory 1 5 1 5 1 5 A B A B A B 2-M To Stop Switch Terminal On Engine (Ground) 3-R To Regulator (Charging) OFF RUN START 4-S To Solenoid (Tab terminal) Figure 7 5-B To Battery (Battery terminal on solenoid) It is not possible to show all of the wiring diagrams or keyswitch combinations that are used by equipment manufacturers. the following wiring diagrams for the most popular Briggs & Stratton engines may be used as a guide when replacing an engine. The additional terminal provides a direct connection for the charging lead at the keyswitch. part number 490066.appear to be identical. it would not function. Note in Figure 2.

START 2+4+5 4 To Solenoid (Tab terminal) *Terminal 1 Grounded Internally 5 To Battery (Battery terminal on solenoid) To Key Switch Case 22 . RUN 2+5 3 To Stop Switch Terminal On Engine 3. Function Switch Position Continuity 1 Ground (Used only with insulated panel) 1. + STARTER MOTOR 12 VOLT BATTERY Typical Dual Circuit Alternator Wiring Diagram Original 5-Pole Key Switch Part# 490066 Superceded to 6-Pole Key Switch. STOP ANTI-AFTERFIRE SWITCH SOLENOID ALTERNATOR TERMINAL DIODE KEY SWITCH 2 3 4 AC OUTPUT 1 5 WIRE DC OUTPUT WIRE RED + RED AMMETER SOLENOID TAB TERMINAL HEADLIGHTS − HEADLIGHT TO BATTERY TO STARTER SWITCH TERMINAL TERMINAL RED SOLENOID RED RED RED . Briggs & Stratton Part# 692318 Key Switch Test Terminal No. OFF *1 + 3 2 To Carburetor Solenoid 2.

RUN 2+5+6 3 To Stop Switch Terminal On Engine 3. Key Switch Test Terminal No. STOP ANTI-AFTERFIRE SWITCH SOLENOID ALTERNATOR TERMINAL DIODE KEY SWITCH 2 3 4 AC OUTPUT RED DC OUTPUT 1 5 WIRE WIRE 6 AMMETER + − RED AMMETER (OPTIONAL) HEADLIGHTS − + RED SOLENOID TAB TERMINAL HEADLIGHT SWITCH TO STARTER TO BATTERY TERMINAL TERMINAL SOLENOID RED RED . note that − and + symbols are reversed. Function Switch Position Continuity 1 Ground (Used only with insulated panel) 1. The + symbol must always be connected to the alternator side. START 2+4+5 4 To Solenoid (Tab terminal) *Terminal 1 Grounded Internally 5 To Battery (Battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output) 23 . OFF *1 + 3 + 6 2 To Carburetor Solenoid 2. + STARTER MOTOR 12 VOLT BATTERY Typical Dual Circuit Alternator Wiring Diagram 6-Pole Key Switch − Briggs & Stratton Part# 692318 With ammeter shown in optional position.

STARTER SOLENOID STATOR STARTER RED BLACK DIODE AC RED OUTPUT WHITE CONNECTOR RED DC LIGHT OUTPUT SWITCH 24 RED RED AMMETER RED BATTERY 4 RED 3 5 6 START SWITCH 2 1 Typical Dual Circuit System .

OFF *1 + 3 2 To Carburetor Solenoid 2. Function Switch Position Continuity 1 Ground (Used only with insulated panel) 1. START 2+4+5 4 To Solenoid (Tab terminal) *Terminal 1 Grounded Internally 5 To Battery (Battery terminal on solenoid) To Key Switch Case 25 . + STARTER MOTOR 12 VOLT BATTERY Typical 16 Amp Regulated Alternator Wiring Diagram 5-Pole Key Switch − Briggs & Stratton Part# 692318 Key Switch Test Terminal No. RUN 2+5 3 To Stop Switch Terminal On Engine 3. STOP ANTI-AFTERFIRE SWITCH SOLENOID TERMINAL ALTERNATOR KEY SWITCH AC OUTPUT 2 3 WIRE 4 YELLOW 1 5 DC OUTPUT RED WIRE REGULATOR/ RECTIFIER + AMMETER SOLENOID TAB − RED TERMINAL TO BATTERY TERMINAL TO STARTER TERMINAL HEADLIGHTS RED HEADLIGHT SOLENOID SWITCH RED RED .

note that − and + symbols are reversed. The + symbol must always be connected to the alternator side. Function Switch Position Continuity 1 Ground (Used only with insulated panel) 1. + STARTER MOTOR 12 VOLT BATTERY Typical 16 Amp Regulated Alternator Wiring Diagram 6-Pole Switch − Briggs & Stratton Part# 692318 With ammeter shown in optional position. RUN 2+5+6 3 To Stop Switch Terminal On Engine 3. STOP ANTI-AFTERFIRE SWITCH SOLENOID TERMINAL ALTERNATOR KEY SWITCH AC OUTPUT 2 3 WIRE 4 YELLOW DC OUTPUT 1 5 RED WIRE 6 AMMETER + − REGULATOR/ RECTIFIER AMMETER (OPTIONAL) SOLENOID TAB TERMINAL − + RED TO BATTERY TERMINAL TO STARTER TERMINAL HEADLIGHTS SOLENOID HEADLIGHT SWITCH RED RED . START 2+4+5 4 To Solenoid (Tab terminal) *Terminal 1 Grounded Internally 5 To Battery (Battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output) 26 . OFF *1 + 3 + 6 2 To Carburetor Solenoid 2. Key Switch Test Terminal No.

Function Switch Position Continuity 1 Ground (Used only with insulated panel) 1. note that − and + symbols are reversed. + STARTER MOTOR 12 VOLT BATTERY Typical 16 Amp Regulated Alternator Wiring Diagram With Charge Indicator Light 6-Pole Switch − Briggs & Stratton Part# 692318 With ammeter shown in optional position. RUN 2+5+6 3 To Stop Switch Terminal On Engine 3. START 2+4+5 4 To Solenoid (Tab terminal) *Terminal 1 Grounded Internally 5 To Battery (Battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output) 27 . OFF *1 + 3 + 6 2 To Carburetor Solenoid 2. The + symbol must always be connected to the alternator side. ALTERNATOR STOP ANTI-AFTERFIRE SOLENOID SWITCH TERMINAL AC OUTPUT CHARGE INDICATOR 2 3 WIRE LIGHT 4 YELLOW 1 5 BLUE WIRE 6 AMMETER REGULATOR/ RECTIFIER + − RAISED RIB SOLENOID TAB RED WIRE AMMETER TERMINAL DC OUTPUT (OPTIONAL) TO BATTERY − + RED TERMINAL TO STARTER TERMINAL HEADLIGHTS SOLENOID HEADLIGHT SWITCH RED RED . Key Switch Test Terminal No.

+ AMMETER STARTER RELAY RED B C D SEAT 28 SWITCH C A A B CLUTCH BRAKE SWITCH LIGHT SWITCH E D A RED C B ELECTRIC BATTERY CLUTCH Typical 10/16 Amp System . 4 GROUND WIRE TERMINAL 3 5 6 RED ALTERNATOR 2 1 RED RED STARTER .

OFF *1 + 3 + 6 2 To Carburetor Solenoid 2. START 2+4+5 4 To Solenoid (Tab terminal) *Terminal 1 Grounded Internally 5 To Battery (Battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output) 29 . Function Switch Position Continuity 1 Ground (Used only with insulated panel) 1. Key Switch Test Terminal No. + STARTER MOTOR 12 VOLT BATTERY Typical 5/9 Amp Regulated Alternator Wiring Diagram With Charge Indicator Light 6-Pole Switch − Briggs & Stratton Part# 692318 With ammeter shown in optional position. RUN 2+5+6 3 To Stop Switch Terminal On Engine 3. TRI-CIRCUIT STATOR ANTI-AFTERFIRE STOP SOLENOID SWITCH TERMINAL ALTERNATOR KEY SWITCH 2 3 AC OUTPUT 4 WIRE GREEN DC OUTPUT RED WIRE 1 5 6 AMMETER REGULATOR/ RECTIFIER + − AMMETER SOLENOID TAB (OPTIONAL) TERMINAL − + RED TO BATTERY TO STARTER TERMINAL TERMINAL HEADLIGHTS SOLENOID HEADLIGHT RED SWITCH RED . The + symbol must always be connected to the alternator side. note that − and + symbols are reversed.

+ STARTER MOTOR 12 VOLT BATTERY Typical Tri-Circuit Alternator Wiring Diagram 6-Pole Switch − Briggs & Stratton Part# 692318 With ammeter shown in optional position. TRI-CIRCUIT STATOR STOP ANTI-AFTERFIRE SWITCH SOLENOID AC OUTPUT TERMINAL WIRE ALTERNATOR KEY SWITCH GREEN 2 3 . note that − and + symbols are reversed. START 2+4+5 4 To Solenoid (Tab terminal) *Terminal 1 Grounded Internally 5 To Battery (Battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output) 30 .DC OUTPUT WIRE + DC OUTPUT 4 WIRE 1 5 HEADLIGHT SWITCH 6 AMMETER + − RED RED AMMETER SOLENOID TAB (OPTIONAL) TERMINAL HEADLIGHTS TO BATTERY − + TERMINAL TO STARTER CLUTCH TERMINAL SWITCH SOLENOID RED RED ELECTRIC CLUTCH . The + symbol must always be connected to the alternator side. Function Switch Position Continuity 1 Ground (Used only with insulated panel) 1. OFF *1 + 3 + 6 2 To Carburetor Solenoid 2. RUN 2+5+6 3 To Stop Switch Terminal On Engine 3. Key Switch Test Terminal No.

RED RED BATTERY RED STARTER STARTER SOLENOID INTERLOCK SWITCH 1 25W RESISTOR PT O SWITCH E 31 4 D A 3 5 C B 2 1 RED START SWITCH WHITE WIRE STATOR CLUTCH GREEN CONNECTOR LIGHT SWITCH Simplified “Tri-Circuit” System .

DC OUTPUT + DC OUTPUT 4 WIRE RED WIRE HEADLIGHT 1 5 SWITCH + AMMETER RESISTOR A HEADLIGHTS − TO BATTERY SOLENOID TAB TERMINAL TERMINAL 32 OFF RED B SOLENOID ON STARTER STARTER MOTOR TERMINAL Note: If clutch switch is in ON position with keyswitch OFF. RED RED battery will discharge through clutch. + − Key Switch Test Switch Position Continuity ELECTRIC CLUTCH 12 VOLT BATTERY 1. anti-afterfire solenoid will not shut off. CLUTCH To prevent this. OFF *1 + 3 2. SWITCH However. START 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Typical Tri-Circuit Alternator Wiring Diagram – With Resistor – 5-Pole Switch − Briggs & Stratton Part# 692318 . Remove anti-afterfire solenoid or convert system to 6 pole switch. route wire B to #2 terminal on key-switch. TRI-CIRCUIT STATOR STOP SWITCH TERMINAL AC OUTPUT ANTI-AFTERFIRE WIRE SOLENOID ALTERNATOR KEY SWITCH SEE NOTE GREEN 3 2 . RUN 2+5 3.

RUN 2+5 3. START 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Typical Tri-Circuit Alternator Wiring Diagram – With Resistor – 6-Pole Switch − Briggs & Stratton Part# 692318 .DC OUTPUT 2 3 WIRE + DC OUTPUT WIRE 4 HEADLIGHT 1 5 SWITCH 6 + AMMETER RESISTOR SOLENOID TAB 33 − RED HEADLIGHTS TERMINAL TO STARTER TERMINAL OFF RED TO BATTERY TERMINAL SOLENOID STARTER ON MOTOR RED CLUTCH RED DPDT SWITCH Key Switch Test + − Switch Position Continuity ELECTRIC CLUTCH 1. OFF *1 + 3 12 VOLT BATTERY 2. TRI-CIRCUIT STATOR STOP AC OUTPUT ANTI-AFTERFIRE SWITCH ALTERNATOR WIRE SOLENOID TERMINAL KEY SWITCH GREEN .

RED RED RED FUSE RED STARTER BATTERY .+ AMMETER RED STARTER RELAY START SWITCH CLUTCH/ BRAKE SWITCH 4 RED B D 3 5 E A C 2 1 D A C B 34 PT O SWITCH PT O CLUTCH A B SEAT SWITCH WHITE WIRE STATOR A B GREEN LIGHT CONNECTOR SWITCH Typical Complex Tri-Circuit System .

w/o EFM w/o EFM with EFM 2 pin. standard 691220 691220 na Used with (RED. standard na 797424 796860 6 pin with oil pressure switch 698330 797460 797492 6 pin with hour meter or oil minder 696576 797461 796960 Associated Parts Shield/Nut Assembly #1 side 796852 796852 796852 Bracket. V-Twin Wire Harness Description M40/44 with #2 side M49 with #1 side M40/44/49 with #1 regulator. side regulator. regulator. regulator out) (Jumper Wire) 691208 797463 797463 6 pin. Hold Down (wire) na 797454 797454 Tie wrap for regulator wires na yes yes (inside blower) 6-pin DEUTSCH connector 6-Pin Deutsch Connections ENGINE CONNECTION EQUIPMENT CONNECTION 6-Pin Deutsch Connections 6-Pin Deutsch Connections ENGINE CONNECTION EQUIPMENT CONNECTION ENGINE CONNECTION EQUIPMENT CONNECTION TERMINAL WIRE END END VIEW FROM WIRE TERMINAL TERMINAL END TERMINAL END WIRE END END END VIEW FROM VIEW FROMTERMINAL END TERMINAL END OIL PRESSURE (GREEN) IF APPLICABLE OIL PRESSURE (GREEN) OIL PRESSURE (GREEN) IF APPLICABLE IF APPLICABLE VOLTAGE REGULATOR VOLTAGE REGULATOR INSTALL SEALING PLUG (RED VOLTAGE WIRE) REGULATOR INSTALLPLUG INSTALL SEALING SEALING PLUG #6IN EMPTY #6 POSITION (RED (RED WIRE) WIRE) IN EMPTY IN #6 EMPTY POSITION POSITION OIL PRESSURE PRESSURE (GREEN) OIL PRESSURE (GREEN) OIL (GREEN) VOLTAGE (RED) VOLTAGE REGULATOR REGULATOR (RED) STARTER STARTER STARTER SOLENOID SOLENOID SOLENOID ( YELLOW WIRE) IGNITION KILL IGNITION KILL ( YELLOW ( YELLOWWIRE) WIRE) (BLACK WIRE)IGNITION KILL * IGNITION*(BLACK) IGNITION (BLACK) * IGNITION (BLACK) STARTER STARTER SOLENOID SOLENOID (YELLOW) (YELLOW) 1 1 4 4 (BLACK WIRE) 1 4 (BLACK WIRE) 2 2 5 5 GROUND (BROWN) FUEL CUT-OFF (GRAY) GROUND (BROWN) FUEL CUT-OFF (GRAY) 2 5 GROUND (BROWN) 3 3 6 6 3 6 * TO KILL * TO KILL ENGINE ENGINE CONNECT TOCONNECT GROUND TO GROUND FUEL SHUT-OFF FUEL SHUT-OFF (GRAY WIRE) (GRAY WIRE) GROUND GROUND (BROWN WIRE) (BROWN WIRE) * TO KILL ENGINE CONNECT TO GROUND FUEL SHUT-OFF DEUTSCH DEUTSCH DEUTSCH DEUTSCH (GRAY WIRE) GROUND 1PD-USA 1PD-USA (BROWN WIRE) 1PD-USA 1PD-USA DEUTSCH DT04-6PDT04-6P DEUTSCH DT06-6S DT06-6S 1PD-USA 1PD-USA DT06-6S DT04-6P 35 .

Models 400000/440000 OHV (See also 696576) 790544 . R An adapter wire. 6-pin WIRE HARNESS 6-Pin Wire Harness Assembly Part# 790544 Adapter wire Installation Guide Female . may be required when connecting the alternator system.white connector Connect leads as shown per your service part number.Wire/Connector-ALT Magnetron® Armature Fuel Solenoid Ground L R Oil Pressure Switch Alternator System 696576 . 300000.Models 290000.red connector Male . & 380000 OHV Vanguard Series Fuel Solenoid Stop Switch Oil Pressure Switch Alternator System 698331 .Models 280000 & 310000 OHV and L-Head Oil Pressure Switch Ground Fuel Solenoid Stop Switch Alternator System 698332 . L Red jumper wire 698330 . illustrated. 350000.Models 420000 & 460000 Oil Pressure Switch Stop Switch Alternator System 36 .Models 400000/440000 OHV (Models equipped with Engine Minder ) Magnetron® Armature Fuel Solenoid Ground Alternator System 698329 .

46 & 49 CAUTION: DO NOT INTERCONNECT ANY UNUSED HARNESS CONNECTORS.Models 21. 42. OIL PRESSURE SWITCH (IF APPLICABLE) GREEN IGNITION (IF NOT IGNITION (IF EQUIPPED WITH FUEL SOLENOID) TOP EQUIPPED WITH FUEL SOLENOID) GRAY GRAY OPEN REGULATOR BLACK (IF EQUIPPED) BLACK GREEN RED RED ORANGE ORANGE BOTTOM DUAL CIRCUIT ALTERNATOR (IF EQUIPPED) 37 . 44. 28. APPLICATION (EQUIPMENT) 6-pin CONNECTOR 695050 . 30. OR IGNITION SYSTEM DAMAGE WILL OCCUR. Tape or shrink tube unused connectors.

2 15 CURRENT FLOW 14 6 DETAIL “K” KEY EACH DIODE ASSEMBLY MUST BE INDIVIDUALLY WRAPPED 6 DIODES DETAIL IN SHRINK TUBING. Typical 6-pin connector CYL. 1 14 6 PIN CONNECTOR CYL. 15 SHRINK TUBING "ROUTE" TO TERMINAL HOLE No's AS SHOWN. F A 38 SEE DETAIL K 3 6 5 2 RED 4 4 D GRAY BLACK 1 JUMPER WIRE BETWEEN 1&4 E 6 3 RED 5 2 E 4 1 WIRE IDENTIFICATION REFERENCE TERMINAL ENGINE TERMINATION POINT RIB A CYLINDER #1 COIL B CYLINDER #2 COIL C CARB SOLENOID SOCKETS MUST BE PUSHED INTO D GROUND HOUSING UNTIL TANGS SNAP E POWER SUPPLY TO REGULATOR OPEN OVER PLASTIC TO INSURE THAT SOCKETS CANNOT F EFM IGNITION PULSE BACK OUT (4 PLACES) . AN ADDITIONAL SHRINK WRAP MUST 14 CRIMPED CONNECTION K ALSO BE ASSEMBLED OVER BOTH DIODE ASSEMBLIES.

4 IGNITION WIRE PRIMARY 5 --- 5 STEPPER MOTOR WIRE D 6 12 VOLT POWER (GND) 6 STEPPER MOTOR WIRE C 7 12 VOLT POWER (+) 8 --- 6 STEPPER MOTOR 2-WAY CONNECTOR 5 ASSEMBLY 6 7 4 1 2 TERMINAL # SIGNAL 1 THERMISTOR (SIGNAL) 2 THERMISTOR (GND) GRAY 3 GRAY 2 CARB SOLENOID 6 7 BLACK GRAY BLACK BLACK THERMISTER EFM PULSE SIGNAL BLACK GROUND (ON CYLINDER SHIELD) 39 GRAY YELLOW YELLOW RED 16 AMP CIRCUIT OPTION STATOR CYLINDER #2 DIODE ARMATURE 5 & 9 AMP RED CIRCUIT OPTION BLACK RED RED DIODE 6 PIN CONNECTOR (ENGINE SIDE) 6 PIN CONNECTOR 5 WIRE COLOR 6 TERMINAL ENGINE TERMINATION POINT RED 4 1 POWER SUPPLY FROM REGULATOR CYLINDER #1 2 CYLINDER #1 & #2 ARMATURE BLACK ARMATURE 1 3 CARB SOLENOID GRAY 3 2 4 POWER SUPPLY FROM REGUALTOR RED 5 OPEN - 6 OPEN - . STEPPER MOTOR WIRE E 1 1 2 1 (12 VOLT (+) INPUT 2 12 VOLT POWER (GND) 2 STEPPER MOTOR WIRE A 3 12 VOLT POWER (+) 3 STEPPER MOTOR WIRE B 2 3 3 4 --. 6-pin wire harness with efm 8-WAY CONNECTOR EFM CONTROL MODULE 8-WAY CONNECTOR TERMINAL # SIGNAL TERMINAL # SIGNAL CARB MANIFOLD ASSEMBLY --.

WIRE CONNECTORS V-TWIN 6 PIN CONNECTOR ENGINE CONNECTION APPLICATION CONNECTION AMP PIN HOUSING (FEMALE-CAP) AMP SOCKET HOUSING (MALE-PLUG) RIB IS AT HOLE #1 TO LIGHT SWITCH HOLE #4 "LIGHT SWITCH" COLOR: ORANGE HOLE #1 "ALTERNATOR" COLOR: RED HOLE #5 "OIL SWITCH" COLOR: GREEN "A" TERMINAL HOLE #2 "MAGNETO" COLOR: BLACK KEYSWITCH "M" TERMINAL HOLE #6 "OPEN" TO OIL LIGHT HOLE #3 "FUEL SOLENOID" COLOR: GREY HOLE #6 "OPEN" KEYSWITCH "L" TERMINAL V-TWIN WITH DUAL 2 PIN CONNECTORS ENGINE CONNECTION APPLICATION CONNECTION AMP PIN HOUSING (FEMALE-CAP) AMP SOCKET HOUSING (MALE-PLUG) TO LIGHT SWITCH HOLE #1 "3 AMP ALTERNATOR AC" COLOR: RED HOLE #2 "3 AMP ALTERNATOR AC" KEYSWITCH "A" TERMINAL COLOR: RED ENGINE CONNECTION APPLICATION CONNECTION AMP SOCKET HOUSING (MALE-PLUG) AMP PIN HOUSING (FEMALE-CAP) HOLE #1 "MAGNETO" COLOR: BLACK KEYSWITCH "M" TERMINAL KEYSWITCH "L" TERMINAL HOLE #2 "FUEL SOLENOID" COLOR: GREY V-TWIN WITH 2 PIN CONNECTOR AND 1 PIN CONNECTOR ENGINE CONNECTION APPLICATION CONNECTION AMP SOCKET HOUSING (MALE-PLUG) AMP PIN HOUSING (FEMALE-CAP) "ALTERNATOR" COLOR: RED KEYSWITCH "A" TERMINAL ENGINE CONNECTION APPLICATION CONNECTION AMP SOCKET HOUSING (MALE-PLUG) AMP PIN HOUSING (FEMALE-CAP) HOLE #1 "MAGNETO" COLOR: BLACK KEYSWITCH "M" TERMINAL HOLE #2 "FUEL SOLENOID" COLOR: GREY KEYSWITCH "L" TERMINAL 40 .

5406515 .5402307 TO MAIN HARNESS ENGINE 5020091 3/8” X 9 3/8” X 9 O/W TO MAIN ENGINE STARTER GROUND HARNESS WHT VIO 5020090 SOLENOID TIE WRAP TIE WRAP 3.799615 . VOLTAGE REGULATOR BIG BLOCK™ (ENGINE) typical 8-pin connector (RED) STARTER GROUND (BROWN) Service Part # 809967 SOLENOID TAB (YELLOW) IGNITION KILL WIRE (BLACK) END OIL PRESSURE (GREEN) OPEN SLOT OPEN SLOT TERMINAL END WIRE TERMINAL END END FUEL CUT-OFF (GRAY) VIEW FROM OIL PRESSURE (GREEN) TERMINAL END CUSTOMER CONNECTION STARTER SOLENOID BATTERY + (ORANGE) STARTER SOLENOID 13 TO FIT INDAK KEY SWITCH BATTERY + (ORANGE) FOR .032 TAB THICKNESS VIEW FROM TERMINAL END BIG BLOCK™ APPLICATION (Equipment) TYPICAL 8-PIN connector (RED) Service Part # 809906 (BROWN) (GREEN) (YELLOW) (BROWN) 41 (BLACK) (BLACK) WIRE END (BLACK) (BROWN) (GREY) (GREEN) (GREY) FERRIS®/SNAPPER PRO® ENGINE TO EQUIPMENT WIRE HARNESS Air-Cooled KAWASAKI AIR-COOLEDKawasaki JUMPER Jumper WIRE Wire HARNESS Harness .00 5.0” Kohler Engine Wire Harness .

5401951 799618 42 IS2000 ELS Jumper .5402519 GROUND 5020907 5020087 5100357 O/W WHT VIO WHITE 3” BLACK 17” YELLOW 14” STARTER WIRE 5021461 SOLENOID END 5020914 5023206 WHT WHITE 6” WHT VIOLET 6” VIO YEL YEL VIO ORANGE/WHITE 3” VIOLET 3” O/W O/W TO MAIN ORANGE/WHITE 6” HARNESS 5020906 ENGINE 5020907 5023171 5023172 IS2000 IS2000 Kawasaki KAWASAKI® 26 HP 26 Jumper Wire Harness .5401204 Briggs & Stratton Jumper Wire Harness .TWR Wire Harness .5403929 TO MAIN ORANGE/WHITE 6” BIG Big Block Kawasaki Jumper BLOCK™/KAWASAKI® JUMPERWire WIREHarness HARNESS.TWR Wire Kawasaki Harness 26HP .5401204 GROUND 5020087 GROUND 5020087 .799617 ELS Jumper .799616 .5402519 HPJUMPER JumperWIRE Wire HARNESS Harness -.5406515 JUMPER .00” Briggs & Stratton Jumper Wire Harness .799619 HARNESS 5020906 ENGINE 5020907 5023171 ORANGE/WHITE 8” 5023172 ENGINE 3/8” X 9 ORANGE/WHITE 8” ENGINE O/W TO MAIN 3/8” X 9 ENGINE HARNESS WHT VIO 5020090 O/W TO MAIN ENGINE WHITE 8” HARNESS WHT VIO 5020090 VIOLET 8” TIE WRAP WHITE 8” VIOLET 8” TIE WRAP 3.00” 3.00 ENGINE TO EQUIPMENT WIRE HARNESS FERRIS®/SNAPPER PRO® 5.0” BRIGGS & STRATTON® EXTENDED LIFE SERIES™ KOHLER® Kohler ENGINE Engine WireWIRE HARNESS Harness . 5020914 ENGINE WHT STARTER GROUND 5020090 SOLENOID VIO YEL ORANG TIE WRAP TIE WRAP VIOLET 3” O/W 3.TWR WIRE HARNESS .5403929 .5401951 TO STARTER SOLENOID GROUND 5020090 TO STARTER 5020087 SOLENOID 5020090 YELLOW 8” WHITE/RED 6” ORANGE/WHITE 6” WHT YELLOW 8” WHITE/RED 6” ORANGE/WHITE 6” BLACK 17” YELLOW 14” TO MAIN WHT VIO YEL VIO WHT STARTER HARNESS TO ENGINE SOLENOID O/W O/W WHT VIO5021517 5020906 TOO/W MAIN O/W YEL VIO WHITE 6” 5023206 5020914 TO ENGINE 5020907 HARNESS VIOLET 6” O/W O/W WHITE 6” 5020906 O/W O/W TIE WRAP 5021517 WHT 5020907 WHITE 6” 5020914 VIOLET 6” TIE WRAP VIOLET 6” YEL VIO O/W Big Block Kawasaki Jumper Wire Harness .

799622 TO MAIN TO MAIN HARNESS HARNESS WHITE 6” WHITE 6” VIOLET 6” 3/8” X 9 43 BLACK 17” 3/8” X 9 VIOLET 6” 3/8” X 9 VIO BLACK 17” 3/8” X 9 TO MAIN O/W WHT VIO TO STARTER GROUND TO MAIN TO ENGINE O/W WHT TO STARTER GROUND HARNESS TO ENGINE 5023171 SOLENOID HARNESS SOLENOID 5023171 5023172 5023172 TIE WRAP ORANGE/WHITE 6” TIE WRAP ORANGE/WHITE 6” YELLOW 9” YELLOW 9” 2X0 5. ORANGE/WHITE 8” ENGINE ORANGE/WHITE 8” ENGINE 3/8” X 9 3/8” X 9 O/W TO MAIN O/W ENGINE TO MAIN ENGINE HARNESS WHT VIO 5020090 HARNESS WHT VIO 5020090 WHITE 8” WHITE 8” VIOLET 8” VIOLET 8” TIE WRAP WRAP FERRIS®/SNAPPER® PRO ENGINE TO TIE EQUIPMENT WIRE HARNESS 3.00” 2X0 5.5401204 HARNESS 5401204 .00” S800S800 KAWASAKI® Kawasaki JUMPER Jumper WireWIRE HARNESS Harness .5404653 TO STARTER TO ENGINE SOLENOID 3/8” X 3” TO MAIN ORANGE/WHITE 3” HARNESS 1/2” X 3” BLACK 9” O/W YEL VIO TO ENGINE WHT BLK VIOLET 5” TIE WRAP YELLOW 9” 1.00” 3.50” .IS20000Z IS20000Z BRIGGS & STRATTON® JUMPER WIRE HARNESS .799621 .00” Briggs Briggs & BRIGGS & Stratton & Stratton STRATTON®Jumper Jumper Wire Wire JUMPER Harness Harness WIRE -.799620 GROUND GROUND 5020087 5020087 BLACK 9” BLACK 9” ORANGE/WHITE 8” ORANGE/WHITE 8” O/W VIO O/W TO MAIN O/W TO TO MAIN VIO O/W HARNESS WHT VIO BLK WHT TO HARNESS HARNESS WHT VIO BLK WHT HARNESS WHITE 8” 5023495 WHITE 8” VIOLET 8” 5023495 5020014 VIOLET 8” TIE WRAP 5020014 TIE WRAP Briggs Briggs & & Stratton Stratton Jumper Jumper Wire Wire Harness Harness -.

5” 44 393814 Wire/Conn Alternator 4. ALTERNATOR HARNESS AND REPAIR LEADS 7.25” 692306 Wire Assembly 7.125” 7.5” 393456 Wire/Conn Alternator 47.25” 45” 45” 691955 Alternator Harness 4.25” 1737446YP Wiring Harness .

5” 46.0” 8.0” 691208 Wire Assembly .5” 398661 Alternator Harness 7.0” 393537 Wire/Connector Alternator 16.0” 399916 Wire/Connector Alternator 45 8. ALTERNATOR HARNESS AND REPAIR LEADS 46.0” 7.0” 698092 Wire/Connector Alternator 7.

5” 398838 Wire Stop 8.0” 398153 Wire Assembly 6.5” 695283 Wire Stop 13.5” 15.5” 14. ALTERNATOR wire assembly and stop wires 16.75” 9.5” 697089 Wire Stop .5” 20.0” 797463 Wire Assembly 8.0” 398808 Wire Stop 46 14.

0” 690807 Wire Stop 7. ALTERNATOR HARNESS stop wires 18.25” 692602 Wire Stop 7.5” 692390 Wire Stop 12.75” 692151 Wire Stop .5” 697397 Wire Stop 14.0” 693010 Wire Stop 47 15.

25” 2.5” 695814 Wire Stop 11.5” 8.25” 2.5” 14. ALTERNATOR wire assembly and stop wires 6.5” 844549 Harness Wiring .25” 692961 Wire Assembly 5.0” 48 695630 Wire Stop 14.5” 12.5” 690791 Wire Stop 2.25” 496381 Wire Stop 5.

WIRE HARNESS AND ASSEMBLIES (BROWN) (RED) (BLACK) (YELLOW) WHITE (ORANGE) 692961 Wire Assembly For 6 Terminal Key Switches (RED) (BLACK) WHITE (YELLOW) (BROWN) (ORANGE) 841318 Wiring Harness For 6 Terminal Key Switches 49 (RED) (BLACK) WHITE (YELLOW) (BROWN) (ORANGE) 691996 Wiring Harness (RED) (BLACK) WHITE (YELLOW) (BROWN) (ORANGE) 691578 Wiring Harness (YELLOW) (Wire Ties) (Halogen Light Bulb) 7001302MA Service Alternator Kit .

CARBURETOR SOLENOID IDLE WHITE BLUE DOWN DEVICE 50 CYCLE – 3000 RPM LOOP MODULE STOP SWITCH GREEN TERMINAL ACTUATOR RED YELLOW ALTERNATOR KEY SWITCH GREY BLACK AC OUTPUT 2 3 WIRES 4 DC OUTPUT 1 5 WIRE STOP SWITCH HARNESS 6 DIODE DIODE REGULATOR/ RECTIFIER SOLENOID TAB TERMINAL BATTERY STARTER TERMINAL TERMINAL IGNITION COILS SOLENOID . The engine must be turned off when cutting yellow cycle loop. Engines equipped with the Performance Control electronic governor control system have no mechanical governor components. The electronic governor provides more responsive governing than a mechanical governor system. then start the engine for the system to reset the engines RPM for 50Hz cycle.PERFORMANCE CONTROL ELECTRONIC GOVERNOR Some Vanguard™ V-Twin™ engines are equipped with the Performance Control™ electronic governor control system for generator or welder applications. By cutting the yellow wire loop. + STARTER MOTOR 12 VOLT BATTERY Performance Control Electronic Governor Wiring Diagram 50 . the control module may be converted to 50 cycle – 3000 RPM generator applications. The control module is equipped with an idle down circuit for applications requiring that feature. The Performance Control electronic governor control system consists of an electronic control module. wiring and stop switch harness and a throttle actuator. The Performance Control electronic governor control system cannot be retrofitted to mechanical governor engines.

Electrical Connector Method of Crimping INCORRECT CORRECTLY CRIMPED CORRECT 51 .

After completing a replacement of a new connector and terminal to a wire. 52 . such as shrink tubing is a nice way of completeing the job professionally. CONNECTOR REMOVING TOOLS & shrink tubing These are samples of tools for removing terminals from plastic connectors. A protective covering.CONNECTOR CRIMPING & WIRE STRIPPING TOOLS These are samples of different wire crimping tools that can be used during a repower or repair.

” This means that in American Wire Gauge every 6 gauge decrease gives a doubling of the wire diameter.460 * (0. but for metric gauges it is the opposite. and air convection and temperature should all be taken into account. such as is used in battery packs. 000. the gauge is 10 times the diameter in millimeters. Note that in AWG the diameter goes up as the gauge goes down. so a 50 gauge metric wire would be 5 mm in diameter. weight. gauges you use -1. -3. Similar to dB in signal and power levels. NOTE: For installations that need to conform to the National Electrical Code. Probably because of this confusion. An approximate form of this formula contributed by Mario Rodriguez is D = . 0000 etc. and every 3 gauge decrease doubles the wire cross sectional area. which is very conservative. As you might guess. you must use their guidelines. -2. In careful engineering the voltage drop.890625)(awg +3). For the 00. insulation temperature limit.460 * (57/64)(awg +3) or D = . which makes more sense mathematically than “double nought. Contact your local electrician to find out what is legal! 53 .AWG Wire Sizes (see table on the next page) AWG: In the American Wire Gauge (AWG). Metric Wire Gauges (see table on the next page) Metric Gauge: In the Metric Gauge scale. you should trade off the resistance and load with size. but is meant for wiring in air.005·92((36-AWG)/39) inch. thermal conductivity. and flexibility. The Maximum Amps for Chassis Wiring is also a conservative rating. diameters can be calculated by applying the formula D(AWG)=. most of the time metric sized wire is specified in millimeters rather than metric gauges. the rated ampacities are just a rule of thumb. thickness. and not in a bundle. The Maximum Amps for Power Transmission uses the 700 circular mils per amp rule. Load Carrying Capacities (see table on the next page) The following chart is a guideline of ampacity or copper wire current carrying capacity following the Handbook of Electronic Tables and Formulas for American Wire Gauge. For short lengths of wire.

90576 0.4 0.15 33.0056 0.0071 0.7 0.57404 20.7 0.45466 32.140 339 1114 0.9 678.92 42 kHz 23 0.22606 130.46 11.02362 6.276392 55 15 2600 Hz 11 0.2043 5.16072 380 302 125 Hz 000 0.056 690 kHz Metric 1.0137 2900 kHz 54 .81 133.45034 3.37 106.13 0.056 690 kHz 35 0.11 0.632 0.496 0.003 6.004 0.3648 9.3951 1.9 212.47 168.18922 0.00492 0.07874 1049 3440 0.8 41.44352 28 4.200 169.51054 25.1239 0.8 2728 0.82676 0.6 2163 0.072 540 kHz Metric 1.8288 2.56984 35 7.588 5.4096 10.0113 0.197 0.035 1100 kHz Metric 1.9 13 kHz 18 0.0228 1750 kHz Metric 1 .4 .39 555.15062 5.0226 0.18034 206.2 338.182 210 kHz 30 0.2485 0.61 0.361 107 kHz 27 0.064 16.9989 3.40386 40.0907 2.0453 1.9 855.32004 64.0983 0.43 0.20864 41 9.005 0.0808 2.752 0.7808 4.29032 4.0285 0.4982 1.684 0.0359 0.00551 .1819 4.0201 0.525 8.16002 260.180 207.9428 16 2.34822 0.1285 3.2893 7.26 0.7239 12.1 538.9 855.0618 0.2 1404 0.51 0.28702 81.2 0.226 170 kHz 29 0.6282 2.21 0.406392 211 119 325 Hz 2 0.36068 51.0277 1400 kHz 38 0.072 1.1019 2.0289 1350 kHz Metric 1.0254 0.27 0.0225 1750 kHz 39 0.30378 1.072 540 kHz 34 0.1143 523.032 0.8 0.034 1150 kHz 37 0.5 27 kHz 21 0.00787 0.58826 0.088 440 kHz 33 0.7 0.54304 0.125 428.16002 260.127 414.01 0.728 0.292 11 1.40728 14 1.8 21 kHz 20 0.8 1360 0.282 32 5.0063 0.202704 328 239 160 Hz 00 0.016 13.1443 3.7 11 kHz 17 0.0159 0.8128 10.17248 22 3.7 8250 Hz 16 0.729 53 kHz 24 0.53 0.66522 0.0 0.3 17 kHz 19 0.1016 659.8 1750 0.0889 831.2294 5.67 84.0175 2250 kHz 40 0.40384 0.9392 7 0.86 0.254 103.752 0.0035 0.0508 1.163 0.322424 245 150 250 Hz 1 0.027624 118 47 810 Hz 6 0. km power Inches mm chassis wiring conductor copper transmission 0000 0.2032 164.598088 64 19 2050 Hz 10 0.91186 8.25 .984 9 1.060496 73 24 1650 Hz 9 0.0089 0.25246 0.1148 0.1 426.2 2198 0.0126 0.0779 0.00394 0.385 20.0641 1.60992 19 2.81508 135 60 650 Hz 5 0.33 0.577 68 kHz 25 0.634096 89 30 1300 Hz 8 0.2576 6.0179 0.0045 0.14 52.62814 2.2 0.288 130 kHz 28 0. Maximum Conductor Conductor Maximum Maximum frequency for Ohms per Ohms per amps for AWG gauge Diameter Diameter amps for 100% skin depth for solid 1000 ft.2639 0.0571 1.14224 329 1079.26592 0.113 340 kHz 32 0.3249 8.33 0.008 0.0142 0.09 0.4 5300 Hz 14 0.9 6700 Hz 15 0.142 270 kHz 31 0.36 66.1 1715 0.1000 670.0031 0.7921 2.1328 47 12 3200 Hz 12 0.872 1.8216 1.2 33 kHz 22 0.8568 2.184 10.0063 0.55 0.00441 0.5 680.049 0.6 0.64516 16.457 85 kHz 26 0.1976 3.126 0.1736 2.255512 283 190 200 Hz 0 0.12 .044 870 kHz Metric 1.091 430 kHz Metric 2.248 0.112 533.00709 0.43 0.62026 0.295928 101 37 1100 Hz 7 0.162 4.64616 158 75 500 Hz 4 0.20 0.0403 1.12 0.26 4.1563 0.4024 1.5 0.7 0.043 900 kHz 36 0.83 268.051 26.3133 1.05232 1.512664 181 94 410 Hz 3 0.17 0.3 4150 Hz 13 0.1144 2.

600rpm 14 volts AC to V AC 14 volts AC minimum DC only Red to Amps 3.600rpm 10 amp DC Wire 2 to 4 amps DC Dual Circuit 2-4 amps DC 14 volts AC Red Volts Black 3.600rpm Other Yellow Wire to V AC Wire 26 volt AC minimum Regulated two output pins with heat sink Shunt on Shunt on 3.600rpm Earth to V AC Wire 14 volts AC minimum 55 From Stator Shunt on Red Volts 3.600rpm Negative to V AC 28 volts AC minimum Terminal Tri Circuit 28 volts AC 3.600rpm Red 300mV Output Negative Negative Test with regulator fully wired.600rpm Red Volts Earth 28 volts AC minimum for 5 amp to V AC 40 volts AC minimum for 9 amp Regulated one output pin From Regulator Shunt on Shunt on 3. Output up to 20 to V Terminal Terminal amps according to battery state .600rpm 2-4 amps DC 10 amp DC 2 to 4 amps DC Red to Amps Red 3.800rpm also quantum 120000 10 amp DC 0.2 amp DC 10 amp DC 1. Output up to 5 or 9 to V Terminal Terminal amps according to battery state From Stator 3.2 amps DC minimum AC only Red Volts Earth 3.0 amps DC minimum DC only Red to Amps 3.600rpm Shunt on Shunt on Wiring & diode Red 300mV up to 5 amps for battery Negative Negative layout varies to V Refer to service & repair instructions for Terminal Terminal additional information From Stator 3.5 amp DC 10 amp DC 1.600rpm 1.600rpm Red 300mV Negative Negative Test with regulator fully wired.600rpm 1.600rpm Red 300mV Negative Negative Test with regulator fully wired.5 amps DC minimum 1/2 amp DC DC only Red to Amps 3. Output up to to V Terminal Terminal 10/13/16 amps according to battery state Red Volts Yellow 3.600rpm Red Volts Either Other 20 volts AC minimum for 10 & 13 amp 30 volts to V AC Pin Pin AC minimum for 16 amp Regulated two output pin From Regulator Shunt on Shunt on 3. Alternator & Connector Tester Settings Tester Leads Speed & Readings SYSTEM 3 & 4 Red to Amps 2.

This conductor: A material that allows the free flow of voltage could be used to charge a battery.18 degrees C. “Word Power” is the natural extension of your thought processes.) while maintaining 1. AC voltage test: A test that uses a volt meter to charging system: A system that replenishes the indicate the voltage potential of the alternator stator. in contact with the commutator. voltage. current. to atom when molecules come in direct contact with each other. fuse): A switch contact with brushes. breaker point ignition system: An ignition system that uses a mechanical switch to control timing of core: The laminations in the generator constituting ignition. 56 . atom: A small unit of a material that consists of commutator: A sectional piece of copper that is protons. changes AC voltage from the battery charge windings (within the STATOR) to DC voltage. Customers will measure us more than we might imagine. measured in amperes (AMPS).GLOSSARY OF TERMS In this day of lightning fast communications and an ever increasing level of sophistication in our day to day activities. electrons. contacts are considered high amperage compared to a relay. alternator: A charging system device that produces AC voltage and amperage. current: The flow of electrons moving past a point bridge rectifier: A device that uses four in a circuit. A C AC sine wave: A symmetrical wave form that capacitor: An electrical component that stores contains 360 degrees. and through vibration. interconnected diodes to change one cycle of AC current into two DC pulses. circuit breaker. mechanical switch. electrical power drawn from the battery during starting and accessory operation. battery loading device: An electrical test tool contactor: A contactor is an electrically operated that applies an electrical load to the battery while switch usually used in control circuits and whose measuring amperage and voltage. cycle: One complete wave of alternating voltage that contains 360 degrees. are reached. cold cranking amps (CCA): The number of amps armature: A rotating part of a DC motor that consists produced by the battery for 30 sec at 0 degrees F of wire wound around an armature shaft. when kinetic battery charge rectifier: A component which energy is passed from atom to atom. B conduction: Heat transfer that occurs from atom battery: An electrical energy storage device. and neutrons. (. brushes: Carbon components. when we are unable to express our knowledge and expertise accurately and concisely. circuit: A complete path that controls the rate and direction of electron flow on which voltage is applied. the spoken word has become one of the most important tools in our toolboxes. coil: A circular wound wire (winding) consisting of amperes: The measurement of the number of insulated conductors arranged to produce lines of electrons flowing through a conductor per unit of magnetic flux. that stops the flow of current any time current limits condenser: A capacitor used in an ignition system. directly connected to many loops of copper wire in automatic switch (circuit breaker. the magnetic structure thereof. time. that carry battery current to operate the starter motor. breaker points: An ignition system component that cradle: The metal frame that surrounds and protects has two points (contact surfaces) that function as a the generator/engine. electrons.2 V per cell. Without a high caliber vocabulary. It stores voltage and resists any change in voltage. communication with our peers and/or our customers can be severely hampered. fuse (automatic switch): A switch that stops the flow of current any time current limits amperage: The strength or intensity of an electric are reached. alternating current (AC): A flow of electrons that reverses direction at regular intervals. Exercising the vocabulary is every bit as important as learning the latest new service procedure.

horsepower (HP): A unit of power equal to 746 dynamo: A machine for converting mechanical watts (W) or 33. eddy current: Undesirable current induced in the metal structure of an electrical device due to the rate ignition armature: A component containing two or of change in the induced magnetic field. with a conductor. be used to convert AC to DC. or other application accessories. or motion) can be produced by the electrolyte: A mixture of water and sulfuric acid remaining two. tester. attached to a electrons: The parts of an atom that have a negative segmented iron core. by the proximity and motion of a magnetic field or electric charge. idle control: A system that controls the idle speed E of the engine in direct relation to the electrical load. ground: A connection. hertz (Hz): The international unit of frequency equal direct current (DC): The flow of electrons in one to one cycle per second. per minute (550 lb. more coils which. lamination stack: An electrical component that full-wave rectification: The process of rectifying consists of thin iron layers used to focus and control AC and recovering the B.000 lb. electric starting system: A group of electrical components activated by the operator to rotate the induction: The production of voltage and current crankshaft when starting an engine. such as the starter motor. electricity: Energy created by the flow of electrons ignition system: A system that provides a high in a conductor. 57 . direction only. The number of complete electrical L cycles per second (cps). inductive field coil: A coil of wire. lead-acid battery: A battery that stores electrical full power outlet: Enables you to draw the full power energy using lead cell plates and sulfuric acid of the generator out of one outlet. electrical symbols: Graphic illustrations used in electrical system diagrams to show the function of a ignition coil: A device used to supply DC voltage to device or component. load: A device that uses electricity. intentional or accidental.D G–I DC amperage test: A test that uses a digital generator: An electrical device that produces an AC multimeter or other suitable test instrument to sine wave as a wire coil is rotated in a magnetic field indicate the current that should enter the battery if or as magnets are rotated inside a wire coil. (H2SO4). induction principle: A theory which states that the voltage potential. induces electrical energy.-ft.pulse of AC that the diode the lines of magnetic flux. induction – a generator. the spark plugs. per energy into electrical energy by electromagnetic second). fuse An excess current protection device with a thin limited angle torque (LAT) motor: A direct current metal strip that melts and opens the circuit when a (DC) motor used to control governor system short circuit or excess current condition occurs. lights. electro-motive force (EMF): The force which causes current to flow in a conductor. F ionization gap: The distance between the ignition free electron: An electron that is capable of jumping armature pole and the secondary pole in the spark in or out of the outer orbit. in other words. voltage spark in the combustion chamber at the proper time. frequency: 1. a magnetic field. charging system that converts AC to DC by blocking one-half of the AC sine wave to allow current to flow diode: An electrical semiconductor device that can in only one direction. that produces a magnetic field electrical charge when current is passed through it. (H2SO4) used in a lead-acid battery. depletion region: The region of a diode which between an electrical circuit and the earth or some separates P-type material and N-type material. all connections to the battery are good. digital multimeter (DMM): A test tool used to half-wave rectifier: An electronic device used in a measure two or more electrical values. blocks. components in an electronic governor system. when acted upon by a magnetic field.-ft. conduction body serving in the place of the earth. any one of the following (current.

magnetic flux: The invisible lines of force in a power: The rate at which work is done. rectifier: An electrical component that converts AC N-type material: A portion of a silicon crystal that to DC by allowing the current to flow in only one has an excess of electrons and a deficiency of direction. parallel circuit: A circuit that has two or more paths resistive load: An applied load that reduces the (branches) for current flow. magneto: An alternator with permanent magnets used to generate current for ignition in an internal P-type material: A portion of a silicon crystal that has combustion engine. Power Transfer System: A system to safely wire magnetism: An atomic level force derived from your generator to your home’s electrical system. regulator/rectifier: An electrical component that nucleus: The center of the atom. manual switch: A switch operated by a person. Three phase conductor. or condition. protons and neutrons. removed. generator set is the voltage at which it is designed to operate. One volt will low amperage. points and a condenser. pulse: Half of a cycle. which connects different parts of the circuit. rear bearing carrier: The casting which houses the neutrons: The neutral parts of an atom which have rotor bearing which supports the rotor shaft. R–S mechanical switch: A switch operated by the rated speed: Revolutions per minute at which the movement of an object. alternating current consists of three different sine series circuit: A circuit having two or more wave current consists of three different sine wave components connected so that there is only one current flows. 58 . Magnetron® ignition system: An ignition system pulsating DC: DC voltage produced by rectifying that uses electronic components in place of breaker (removing) one-half of an AC sine wave. no electrical charge. an excess of protons and a deficiency of electrons. millivolt: An expression meaning 1/1000th of a volt. permanent (hard) magnet: A magnet that retains secondary winding: A coil in which high voltage is its magnetism after a magnetizing force has been induced for use at the spark plug. protons: The parts of the atom that have a positive electrical charge. and resistance in any resistance (R): The opposition to the flow of circuit. chemical state. the atomic structure and motion of certain orbiting electrons in a substance. different in phase by120 degrees from path for current flow. protons.M–N polarity: The state of an object as negative or positive. self-inductance: A magnetic field created around phase: The uniform periodic change in amplitude a conductor whenever current moves through the or magnitude of an alternating current. electrons. compared to a contactor. current. each other. polarity-sensitive circuit: A circuit that does not operate properly when exposed to the wrong polarity. pathway: A conductor (commonly copper wire). set is designed to operate. possibility of the alternator system delivering full amperage through the circuit. reserve capacity: The amount of time a battery can produce 25A at 80 F (26 degrees C). rotor: The rotating element of a generator. relay: An electrically operated switch usually used in O–P control circuits and whose contacts are considered Ohm: Unit of electrical resistance. magnet: A material that attracts iron and produces a magnetic field. magnetic field. which consists of contains one or more diodes and a zener diode. cause a current of one flow through a resistance of one ohm. magnetic field: An area of magnetic force created and defined by lines of magnetic flux surrounding a potential energy: Stored energy a body has due to material in three dimensions. Ohm’s law: A law that states the relationship between voltage. its position. milliamp: An expression meaning 1/1000th of an rated voltage: The rated voltage of an engine amp.

stop. trigger: A magnetic pick-up located near the crankshaft pulley that senses and counts crankshaft rotation. troubleshooting: The systematic elimination of the various parts of a system or process to locate a malfunctioning part. T–Z temporary (soft) magnet: A magnet that can only become magnetic in the presence of an external magnetic field. voltage regulator: A component which automatically short circuit: An undesirable complete circuit path maintains proper generator voltage by controlling that bypasses the intended path and has very little the amount of DC exitation to the rotor. In AC equals effective volts times two output terminals if a source. stator: An electrical component that has a continuous copper wire (stator winding) wound on separate stubs exposing the wire to a magnetic field. resistance. applied. single phase: An AC load. winding consists of a number stator coils and their interconnections. 59 . vibration mount: A rubber device located between the engine or generator and the cradle to minimize vibration. induced in the secondary windings and directs a high voltage charge to the spark gap at the tip of the zener diode: A semiconductor that senses voltage spark plug. Stator to the ground electrode on the spark plug. switch: Any component that is designed to start. producing device. spark tester: A test tool used to test the condition of the ignition system on a small engine. 1. spark gap: The distance from the center electrode winding: All the coils of a generator. using a magnetic field produced by a coil. voltage regulation system: A system that controls silicon controlled rectifier (SCR): A semiconductor the amount of voltage required to charge the battery that is normally an open circuit until voltage is with a regulator/rectifier. starter motor: An electric motor that drives the engine flywheel when starting. or source of power watt: Unit of electrical power. parallel. In DC equals volts normally having only two input terminals if a load or times amperes. with internal contacts opened or closed. effective amps times power factor times a consistent solenoid: A device that converts electrical energy dependent on the number of phases.series/parallel circuit: A circuit that contains a voltage: The amount of electrical pressure in a combination of components connected in series and circuit.000 watts. Rotor windings consist of all spark plug: A component that isolates the electricity windings and connections on the rotor poles. which switches it to the conducting state in voltage source: A battery or some other voltage one direction. starter solenoid: An electrical switch. 1 kilowatt – into linear motion. to measure the state of battery charge at the battery terminals. volt (V): The unit of measure for electrical pressure difference between two points in a conductor or device. or redirect the flow of current in an electrical circuit.

60 .

com 2 Yellow Wires each 290000 430000 430000 300000 520000 520000 Scan the tag below 350000 580000 580000 380000 470000 540000 841170 For Engine Series V TWIN VANGUARD™: • SMALL: 7/8” x 11/16” (22 x 18 mm) • SMALL: 7/8” x 21/32” (22 x 17 mm) 2 White Connector 825084 Since 2000 825479 Since 2002 • MEDIUM: 1-1/16” x 11/16” (27 x 18 mm) • MEDIUM: 7/8” x 29/32” (22 x 23 mm) 841178 Since 2004 4 Yellow Wires. MS-2288FL .5 Amp DC unregulated Output @ 2800 rpm Engine 97700 99700 White Connector 1 Red Wire 0. Black Connector Black Connector Black Connector 1 Orange Wire White Connector White Connector White Connector charge indicator light Yellow Sheath 1 White Wire. 1 Green Wire Update Literature from CE on your smartphone! 10. Yellow Sheath 1 White Wire. 13. Engine 115 Volts 60 Hz. 4 Amp DC regulated Engine 115400 5 or 9 Amp Regulated Alternator Green Connector 5 or 9 Amp regulated.50 Amp Regulated/ Inverter Alternator 40 Amp Alternator 60 Amp Alternator Flywheel / Magnets Download a free app to your 20 -50 Amp DC regulated Engine 40 Amp DC regulated Engine 60 Amp DC regulated Engine 2 White Connectors smartphone from 2dscan. 2 Green Wires.) 250000 696458 13 A Since 1979 Red Wire = 8 Amp DC regulated for battery 400000 280000 Since 1995 793658 2 Black Connectors Update Literature from 16 A Since 1983 Quad Circuit Since 1984 Small magnets Quad Circuit 20 Volts AC @ stator 420000 460000 825004 Since 1998 825003 696579 Large magnets 795498 Since 2007 2 Black Wires. 1 Red Wire 825524 Since 2002 825577 Since 2002 • LARGE: 1-1/16” x 15/16” (27 x 24 mm) • LARGE: 1-3/32” x 29/32” (28 x 23 mm) Note : Unless specified.com under Customer Education. 1 Green Wire 1 Orange Wire 1 Orange Wire Black Connector Black Connector 1 Black Wire 1 Black Wire White Connector Orange Connector Yellow Connector 2 Yellow Wires 1 Orange Wire 691573 2 Yellow Wires 697261 1 Red Wire Black Connector Red Connector 809176 White Connector 1 Blue Wire 1 Black Wire 697992 1 Red Wire Connector Orange 1 Orange Wire White Connector 2 Red Wires Yellow Connector Black Connector Black Connector 2 Black Wires White Connector CHANGE BRAND FEATURE 697992 White Connector 1 Black Wire Black Connector 697992 White Connector Yellow Sheath 1 White Wire. on-demand. 1 Brown Wire. 1 Black Wire 691991 Since 1989 794103 Alternator outside the flywheel 791743 Since 2007 793640 Since 2007 494254 Since 1988 394250 Since 1979 System 3® / System 4® ➤ Here is a glimpse of the available features on 0. 13 and 16 A DC Regulated or Quad Circuit Alternator Engine (10 A.) 14 Amp Regulated Alternator 20 Amp Regulated Alternator Download a free app to your phone from 2dscan. 1 Red Wire 150000 391507 170000 Diode 15X000 1Black Wire 170000 1 Red Wire 210000 201000 White Connector 190000 391507 20X000 190000 Diode 391507 210000 1 Black Wire. White Connector White Connector 2 Red Wires 1 Red Wire. Yellow Sheath 1 White Wire. MS-2288FL. Tri-circuit 698315 Engine 110000 Green Connector Black Wire 5 or 9 Amp Regulated or Tri-circuit Alternator 5 or 9 Amp DC regulated. Tri-circuit 698315 Engine 160000 117400 1 Black Wire 120000 691955 170000 1 Green. No smartphone? 2 Black Wires Yellow Connector 2 Yellow Wires 190000 280000 430000 520000 2 Yellow Wires.2 Amp DC unregulated Engine 104700 130000 Diode 391507 3 Amp DC unregulated Engine 130200 100600 200000 20X400 Red Connector 100800 21X400 1 Black Wire 110000 Red Connector 120000 ➤ Interact via the internet for a variety of Diode 391507 2 Red Wires.com indicated a repeat test is advised before proceding any further. 1 Red Wire Red Connector Red Connector Since 2000 Since 1974 695466 1 Red Wire 790320 Since 2004 715194 1 Red Wire 715798 Since 2001 715262 Since 1988 1 Red Wire Small magnets Medium magnets 13 Amp Power Link™ Alternator White Connector 115 Volts .000s of technical and service documents with 2 diodes leading to 1 Red Wire and 9 Amp DC regulated Green Connector 350000 1 White Wire 380000 1 Yellow Wire Red Wire = 2-5 Amp DC unregulated for Red Connector 1 Red Wire 400000 battery charge Yellow Connector Small magnet 28 Volts AC White Wire = 2-5 Amp DC negative for lights 420000 Since 1994 5 Amp DC regulated Since 1988 (5 & 9 Amp) 440000 715255 1 Red Wire. 1 Green Wire White Connector 1 Blue Wire White Connector 2 Red Wire White Connector 2 Red Wires.com Alternator Chart Your “One YourStop” Information “One Stop” Source Information Source Briggs & Stratton has developed a powerful and flexible private web-based portal for its You can order this chart from your source of supply or on family of products. Standard data rates may apply. 1 Red between Armatures 190000 118000 150000 210000 185400 200000 220000 • Re-powering and replacement engine look-up 187400 210000 280000 300000 Diode 391507 691188 794360 Green Connector 1 Yellow Wire 250000 256000 280000 290000 Red Connector 1 Red Wire 300000 715200 691188 Small magnet 28 Volts AC 310000 794360 Tri-circuit Diode Wire 5 Amp DC regulated 320000 Green Connector Large magnet 40 Volts AC 330000 • 1. 0. ThePowerPortal. The values indicated are minimium values.5 Amp DC unregulated Engine 110000 120000 White Connector 1 Black Wire 1. Engine 691573 13 Amp DC regulated White Connector 13 Amp DC regulated 691185 13 Amp DC regulated 2 Yellow Wires 697261 13 Amp DC regulated Black Connector 44X700 2 Yellow Wires 35X400 305000 35X700 Ivory sheathed wires 697261 Black Connector 697261 Black Connector Orange Connector 356000 2 Red Wires. 1 Green Wire Orange Connector 2 Red Wires. Briggs & Stratton ThePowerPortal. 16 Amp DC regulated. Small Magnets = 20 Volts AC @ stator and 250000 280000 303000 310000 350000 2 Black 10 Amp DC regulated Medium Magnets = 20 Volts AC @ stator 290000 320000 351000 Connectors and 13 Amp DC regulated 303000 350000 380000 2 Black Wires Large Magnets = 30 Volts AC @ stator and 691362 1 Red Wire 1 Red Wire 808877 16 Amp DC regulated 310000 380000 White Connector 470000 320000 400000 White Connector 2 Yellow Wires 540000 Yellow Connector Yellow Connector 2 Yellow Wires 2 Yellow Wires 330000 420000 1 Red Wire 1 Red Wire 610000 793660 Double White Connector 350000 460000 1 Black Wire White Connector 1 Red Wire (charge) 1 Yellow Wire 1 Brown Wire 1 Blue Wire (charge indicator light) 380000 (QUAD) 2 Blue Wires 1 Orange Wire 400000 170000 1 Green Wire 1 Red Wire 420000 190000 Yellow Connector 2 Yellow Wires 10 A Since 1978 White Connector 460000 220000 397809 Black Wire = 8 Amp DC unregulated for lights (13 A. 697992 697810 Since 2002 1 Black Wire.4 Amp DC unregulated Engine 170000 Red Connector 1 Red Wire 2 .5 Amp DC unregulated Engine 12X400 15X400 1. all tests must be carried out with the engine running at 3600 rpm.60 Hz. 1 Green Wire White Sheath 1 Blue Wire White Connector 1 Blue Wire. 2 Red Wires. 1 Red Wire 290000 303000 20H400 21A400 493219 220000 290000 691573 790325 Red Connector Red Wire 580000 310000 Text XXXXXXXX to 00000.service parts and/or whole goods look-up and ordering 420000 330000 460000 2 White 350000 2 White 2 White Connectors 2 White Connectors Connectors 380000 Connectors Since 1974 1 Red Wire 1 Red Wire 1 Red Wire 46X700 793118 1 Red Wire 391595 698230 Since 2002 1 Yellow Wire 696742 Since 2002 1 Yellow Wire 696459 Since 2007 1 Yellow Wire Since 2007 1 Yellow Wire Small magnets 1 Black Wire 1 Black Wire 1 Black Wire 795498 1 Black Wire • Technical publications search 4 Amp Regulated Alternator Brass Connector Plastic sleeves Green Wires to regulator. Quad-Circuit 160000 220000 2 Blue Wires 14 Amp DC regulated Engine 20 Amp DC regulated Engine Black Connector 20 Amp DC regulated Engine Yellow Connector (regulated battery charge but unregulated lights) 170000 250000 White Connector 2 Black Wires Scan the tag to right. If the value measured is lower than www. Engine 115 Volts 60 Hz. 2 Yellow Wires.qxp 10/23/2008 10:24 Page 1 Features ➤ Secure. 1 Red Wire 210000 21X000 210000 220000 White Connector end products White Connector 220000 240000 1 Black Wire Diode 391507 1 Black Wire.11/08 . 24x7 access to meaningful BRIGGS & STRATTON ALTERNATOR CHART DC only Alternator information and functions for all of our products. 1 Red Wire CE on your smartphone! 20 . 1 Black Wire White Connector business transactions.5 Amp DC unregulated Output @ 2800 rpm Engine 90000 Diode 391507 3 Amp DC unregulated Engine 110000 DC only Alternator 2 . 1 Red Wire 243000 250000 250000 790292 280000 280000 790292 790292 290000 790292 310000 300000 320000 310000 400000 320000 • E-parts . 1 Black Wire 698314 Since 2002 Large magnet 40 Volts AC 696457 Small magnets 9 Amp DC regulated 1976 Tri-circuit 460000 10 Amp Alternator what’s new? Yellow Connector 10 Amp DC regulated Engine Black Connector 10 Amp DC regulated Engine Yellow Connector 10 Amp DC regulated Engine No Connector 10 Amp DC regulated Engine Yellow Connector 10 Amp DC regulated Engine High Output 399916 To be ordered separately 2 Black Wires 399916 Shipped loose 2 Black Wires 110000 2 Black Wires 120000 117400 23X400 2 Green Wires 230400 Green Wires 120000 138400 24X400 240400 200000 185400 210000 691185 691185 691185 790325 Yellow Connector Yellow Connector Yellow Connector 2 Yellow Wires 2 Black Connectors 2 Yellow Wires 2 Yellow Wires Red Connector 2 Black Wires. Engine White Connector 115 Volts 60 Hz. 1 Green Wire 841833 Since 2007 809175 Since 2007 1 Black Wire. ThePowerPortal.com 691185 10.com.thepowerportal. 1 Red Wire 2 Yellow Wires 1 Black Wire. 1 Green Wire 841588 Since 2007 1 Black Wire.) (16 A.electronic warranty claim filing for engines and unregulated White Connector 14 Volts AC unregulated 14 Volts AC unregulated 14 Volts AC unregulated 14 Volts AC unregulated 160000 201000 1 Black Wire.4 Amp DC unregulated Engine 170000 110000 120000 White Connector 120000 Red Connector 190000 190000 the brands for which you provide sales and/or 200000 1 Red Wire 150000 1 Red Wire 210000 210000 Diode 391507 White Connector 210000 200000 220000 220000 1 Black Wire Red Connector 240000 240000 1 Red Wire Diode 391507 250000 250000 service for: E-parts Look-Up Diode 280000 280000 391507 300000 300000 310000 310000 326000 326000 350000 350000 380000 380000 • Brand specific product registration & rebate submission Since 1981 397880 695730 Since 2000 694457 Since 1999 696578 Since 1973 393809 Since 1978 Alternator outside the flywheel AC only Alternator Dual circuit Alternator 14 Volts AC Engine 2 – 4 Amp DC / 5 Amp AC Engine 2 – 4 Amp DC / 5 Amp AC Engine Diode 2 – 4 Amp DC / 5 Amp AC Engine 2 – 4 Amp DC / 5 Amp AC Engine White Connector • eClaim .4 Amp DC unregulated Engine 110000 2 .

LTD Delta (Vancouver) BC V3M 6R9 Power Source Canada. POWER SOURCE CANADA. 6509-A Northpark Boulevard Steve Krcelic 800-288-5310 4.ed@basco. SEDCO. Suite 100 Robert Ortolani 262-834-4394 Mequon (Milwaukee) WI 53092 Magneto Power. Inc. PREFERRED POWER. 225 Henry D. LLC 911 Lund Boulevard. MIDWEST ENGINE WAREHOUSE Aurora (Chicago) IL 60504 Midwest Engine Warehouse-IL 700 Enterprise Street Tom Ziemann 630-862-3100 Edwardsville (KC) KS 66111 Midwest Engine Warehouse-KS 9630 Woodend Road Tom Ziemann 913-543-7600 Visalia CA 93291 Midwest Engine Warehouse-CA 7101 W. 225 Henry D.S. BRIGGS&STRATTON CUSTOMER EDUCATION CORPORATION post office box 702 milwaukee. Avery Street Greg Muse 800-338-5168 2. INC Castleton NY 12033 Atlantic Power. Inc.com MS-0415-02/11 Copyright ©2011. Suite 100 Robert Moe 262-834-4300 Tualatin (Portland) OR 97062 Magneto Power. LLC Anoka (Minneapolis) MN 55303 Magneto Power.W. Unit 1 Mike Gulley 905-829-0006 5. Inc. . All rights reserved. LLC 1000 W. Inc. Suite 300 Robert Moe 800-248-4016 Dallas TX 75235 Magneto Power. ATLANTIC POWER. LTD 2815 Bristol Circle. CENTRAL POWER SYSTEMS Columbus OH 43228 Central Power Systems 3700 Paragon Drive Pat Earnest 614-534-2152 Tampa FL 33610 Central Power Systems of 4751 Oak Fair Boulevard Ray Coyle 614-534-2140 Florida 7. CSSD / IDN EDUCATIONAL IDN Network DIRECTORS DELTA BRITISH COLUMBIA ALBERTA MANITOBA SASKATCHEWAN ONTARIO QUEBEC TUALATIN A OAKVILLE ANOKA CASTLETON MEQUON COLUMBUS WEST VALLEY CITY EDWARDSVILLE PENDERGRASS Magneto Power MWE Preferred Power Power Source Canada Atlantic Power Central Power Systems SEDCO 9/09 1. Donges Bay Road. Doe Avenue John Reid 800-683-8484 West Valley City (SLC) UT 84120 Midwest Engine Warehouse-UT 3626 Parkway Boulevard Tom Ziemann 801-886-2350 3. Robertson Boulevard Mark Thomas 800-346-4260 01/11 ENGINE ALTERNATOR REPOWER GUIDE Printed in the U. 20 Empire State Boulevard Art Falk 800-456-5692 6. INC Charlotte NC 28216 Preferred Power. LLC “West” 9991 S. LLC of Texas 11011 Regency Crest Drive. Magneto Power. Robertson Boulevard Wayne Crosby 800-346-4260 Pendergrass (Atlanta) GA 30567 SEDCO. INC Pendergrass (Atlanta) GA 30567 SEDCO. LTD 300-1628 Derwent Way Mike Gulley 604-520-1294 Oakville (Toronto) ON L6H 6X5 Power Source Canada. WI 53201 USA 800 934 7730 | cust.A.